Mekhanobr-Polimet Research and Production, Dnepr, Ukraine:

E. F. Chizhik, Director, Candidate of Engineering Science, E.chizhik_mehanobr@i.ua

The current-level technologies of ore ball milling require novel understanding of the fill flow inside a mill, as well as the structure–lining material–process variables interaction. It is necessary to know: which physical phenomena cause wear of mill lining to evaluate the wear rate; which surface ensure milling; whether the flow is constant in time as the loading due to flow can both increase and decrease in the course of the mill rotation. The paper presents a new concept of the destruction mechanism of lining in drum mills, and on this basis, a wavy design of rubber lining is proposed. For the first time, the laboratory tests were carried out to determine the relative wear resistance of rubbers in the hydroabrasive environment. To select the parameters of rubber linings, the influence of the impact energy on the fracture resistance of the lining surface is investigated, and the mathematical relations to calculate coefficient of energy transfer to the metal structure of the machine are presented. The increased capacity of mills in terms of feed and finished size output with the Polymet wavy rubber linings is substantiated to be the result of the forced change in flow layers inside the mill over the work surface composed of elastic component (rubber) and rigid component (metal). The results of industrial tests of mills with the wavy structure of rubber linings with their work surface pregnant with balls or vulcanized metal inserts (Polymet) are presented. A promising technology with the use of screw extruders (syringes) for manufacturing of linings, dividing and discharge grids, sieves and other structurally complex products based on wear-resistant rubbers by filling molds under pressure has been proposed. This ensures high quality products without the need for increased material consumption per half-way product with direct molding technology.

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