Journals →  Gornyi Zhurnal →  2021 →  #11 →  Back

ArticleName Rubber linings for ball mills: New designs and production technologies
DOI 10.17580/gzh.2021.11.05
ArticleAuthor Chizhik E. F.

Mekhanobr-Polimet Research and Production, Dnepr, Ukraine:

E. F. Chizhik, Director, Candidate of Engineering Science,


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.

keywords Ore mill, rubber lining, mill feed, flow dynamics, wear, impact resistance

1. Harder J. Trends in the Crushing of Mineral Ores. Mineral Processing. 2016. No. 5. pp. 21–26.
2. Zeren Chen, Guoqiang Wang, Duomei Xue, Da Cui. Simulation and optimization of crushing chamber of gyratory crusher based on the DEM and GA. Powder Technology. 2021. Vol. 384. pp. 36–50.

3. Owusu K. B., Karageorgos J., Greet C., Zanin M., Skinner W. et al. Predicting mill feed grind characteristics through acousti c measurements. Minerals Engineering. 2021. Vol. 171. 107099. DOI: 10.1016/j.mineng.2021.107099
4. Khaymovskiy S. S. Autogenous grinding mill process control practices. Tsvetnye Metally. 2021. No. 3. pp. 38–42. DOI: 10.17580/tsm.2021.03.03
5. Midyukov D. O., Umysheva A. A., Chikildin D. E., Smirnov Yu. A. Ore preparation at Talnakh Concentrator with the semi-autogeneous grinding introduction. Tsvetnye Metally. 2018. No. 6. pp. 27–31. DOI: 10.17580/tsm.2018.06.03
6. Yushkova O. V., Isaeva L. A., Polyakov P. V., Avvakumov E. G. The influence of mechanical activation on the dust index and the dissolution rate of alumina in the molten cryolite. Tsvetnye Metally. 2018. No. 8. pp. 63–68. DOI: 10.17580/tsm.2018.08.08
7. Bortnikov A. V., Samukov A. D. Vibration disinte gration in ore-crushing at concentrators. Obogashchenie Rud. 2018. No. 5. pp. 3–10. DOI: 10.17580/or.2018.05.01
8. Penkin N. S. (Ed.). Enhancement of wear resistance of mining and processing machines. Moscow : Nedra, 1992. 265 p.
9. Chanturia V. A. Innovation-based processes of integrated and high-level processing of natural and technogenic minerals. Gornyi Zhurnal. 2015. No. 7. pp. 29–37. DOI: 10.17580/gzh.2015.07.05
10. Eriksson K.-G., Marklund G., Grebenshchikov A. L., Fishchev V. Yu. Development of mill lining systems. Gornaya promyshlennost. 2003. No. 1. pp. 24–58.
11. Gazaleeva G. I., Tsypin E. F., Chervyakov S. A. Ore preparation. Crushing, screening, beneficiation. Ekaterinbur : UTSAO, 2014. 912 p.
12. Chanturiya V. А., Vaisberg L. A., Kozlov А. P. Promising trends in investigations aimed at all-round utilization of mineral raw materials. Obogashchenie Rud. 2014. No. 2. pp. 3–9. DOI: 10.17580/or.2014.02.01
13. Shinkorenko S. F. Hydrodynamics of work medium in wet ball mills. Gornyi Zhurnal. 2002. No. 7. pp. 19–24.
14. Abbott M. B. Computational Hydraulics: Elements of the Theory of Free Surface Flows . London : Pitman Publishers, 1979. 324 p.
15. Kislyi A. A. Free vibrations in viscous and asymmetric dry friction. Strength of Materials. 1994. Vol. 26, No. 3. pp. 223–225.
16. Rajamani R. K., Mishra B. K. Millsoft-simulation software for tumbling-mill design and trouble shooting. Mining Engineereng. 1999. Decembre. pp. 41–47.
17. Kopchenkov V. G. Model of the wear of rubber under direct impact by a stream of solid particles. International Polymer Science and Technology. 2004. Vol. 31, No. 3. pp. 24–27.
18. Vaisberg L. А., Ustinov I. D. Introduction to mineral separation technology. Saint-Petersburg : Russkaya kollektsiya, 2019. 168 p.
19. Prigogine I. The Еnd of Сertainty : Time, Сhaos, and the New Laws of Nature. New York : The Free Press, 1996. 207 p.
20. Chizhik E. F., Semenyuk E. A. Model of polymeric coating heating in the flow of abrasive particles. Soviet Journal of Friction and Wear. 1983. Vol. 4, No. 5. pp. 950–952.
21. Semenyuk E. A., Chizhik E. F. Theoretical estimate of comparative wear resistance of rubber and steel linings under impact loading. Mineral Processing : Collected Papers. Kiev : Tekhnika, 1982. Iss. 31. pp. 103–106.
22. Chizhik E. F. Drum ore shredding mill with rubber lining. Barnaul, 2005, 359 pp.
23. Pivnyak G. G., Vaisberg L. А., Kirichenko V. I., Pilov P. I., Kirichenko V. V. Grinding. Energy and technology : tutorial. Moscow : Ruda i Metally, 2007. 296 p.
24. Beckmann G., Kleis I. Abtragverschleiss Von Metallen. Leipzig, 1984. 187 s.
25. Schwedes W. H., Owen E. I. How to choose electric drives for large grinding mills. Part I. Engineering and Mining Journal. 1973. Vol. 174, No. 12. pp. 86–91.
26. Chizhik E. F. Evaluation of agreement between steel ball sizes and linings in ore mills. Mineral Processing : Collected Papers. Kiev : Tekhnika, 1982. Iss. 30. pp. 25–28.
27. Malyshev V. P., Zubrina Yu. V., Makasheva A. M., Kaykenov D. A. Self-organization of physical process in ball milling. Resource-Saving Technologies in Ore Dressing and Metallurgy of Non-Ferrous Metals : International Conference Proceedings. Almaty : Arko, 2015. pp. 40–42.

Language of full-text russian
Full content Buy