A method for evaluating performance of grinding media based on wear mechanism

Abstract

The application belongs to the technical field of grinding, and specifically discloses a grinding medium performance evaluation method based on a grinding mechanism, which comprises defining grinding medium wear resistance performance indexes W , grinding efficiency indexes E , energy consumption indexes P and service life indexes L ; the performance indexes are correspondingly weighted by using weight values to obtain a comprehensive evaluation index of the grinding medium S : selected grinding medium and corresponding W , E , P and L are obtained, the weight values of the performance indexes of the grinding medium are determined α W , α E , α P , α L , the comprehensive evaluation index of the grinding medium is calculated by using a formula 1 S ; the selected grinding medium is subjected to experiments to determine actual performance indexes, the actual performance indexes are substituted into the formula 1 to obtain actual comprehensive evaluation indexes S’ , the comprehensive evaluation index of the selected grinding medium is calculated S , and the grinding medium S is compared with S’ to evaluate the evaluation accuracy and reliability of the model. The application has the characteristics of less calculation, objective and accurate evaluation results and strong guidance.

Description

Technical Field

[0001] This invention belongs to the field of grinding technology, specifically relating to a grinding media performance evaluation method based on wear mechanism that requires less computation, provides objective and accurate evaluation results, and offers strong guidance. Background Technology

[0002] Grinding, as a core step in mineral processing, has always been a focus of industry attention due to its efficiency and cost. Grinding media, as a direct participant in the grinding process, has a decisive impact on grinding efficiency and energy consumption. With the increasing depletion of mineral resources and the continuous rise in processing costs, how to optimize grinding media to improve grinding efficiency and reduce energy consumption has become a hot research topic in the mining industry.

[0003] Common grinding media can be categorized into metallic media, non-metallic media, and composite media based on their material properties. Metallic media, primarily including steel balls and bars, possess excellent wear resistance and high density, exhibiting high grinding efficiency when processing ores with high hardness. However, metallic media are prone to corrosion in certain grinding environments and are relatively expensive. Non-metallic media, such as ceramic balls and natural stone, are more suitable for processing soft materials or materials requiring protection from metal contamination due to their lower density and good chemical stability. Composite media combine the advantages of both metallic and non-metallic materials, possessing excellent wear resistance and impact resistance, thus adapting to a wider range of grinding conditions and requirements. Furthermore, each type of grinding media exhibits different performance characteristics based on its physical and chemical properties: for example, high-carbon steel balls, due to their high density and hardness, are widely used in coarse grinding processes; while ceramic media, with their good wear resistance and lower density, are suitable for fine and ultrafine grinding. Different media shapes (such as spherical and rod-shaped) also affect grinding efficiency. Spherical media have good performance under various grinding conditions due to their filling rate and motion state in ball mills, while rod-shaped media show higher efficiency in certain specific applications due to their line contact characteristics.

[0004] Wear mechanisms play a central role in the performance evaluation of grinding media. The basic concept revolves around the phenomenon of media gradually losing material during the grinding process due to physical or chemical effects. Wear processes are complex, typically involving various types such as abrasive wear, impact wear, and corrosive wear. Abrasive wear occurs between the grinding media and the material being ground or within the mill, caused by the scraping of surfaces by hard particles or sharp edges due to relative motion, resulting in material stripping. Impact wear is the loss of material caused by the intense impact forces generated on the media surface during the throwing or collision of grinding media within the mill. Corrosive wear involves chemical or electrochemical reactions and is particularly prominent in grinding environments containing corrosive media. Different grinding conditions and media types lead to differences in wear mechanisms, thus affecting the durability of grinding media and grinding efficiency: for example, in high-speed ball mills, impact wear may be the dominant wear mechanism; while in lower-speed rod mills, abrasive wear may be more significant; corrosive wear may become important in grinding processes involving acidic or alkaline slurries. A thorough understanding of various wear mechanisms allows for more effective selection and design of grinding media, reducing wear, extending service life, and improving grinding efficiency.

[0005] Different wear mechanisms have varying effects on grinding media wear, and understanding the characteristics of these mechanisms is crucial for selecting and designing suitable grinding media. Therefore, in-depth research into the wear mechanisms of grinding media and the exploration of highly efficient and wear-resistant grinding media are of great significance for improving the overall technical level and economic benefits of the mineral processing industry. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a grinding media performance evaluation method based on wear mechanisms that requires less computation, provides objective and accurate evaluation results, and offers strong guidance.

[0007] The objective of this invention is achieved as follows: it includes defining performance indicators, constructing an evaluation model, predicting grinding media, and engineering evaluation steps, specifically including:

[0008] A. Define performance indicators: Define the wear resistance index of grinding media. W Wear efficiency index E Energy consumption index P and lifespan index L ;

[0009] B. Constructing the evaluation model: Weighting the aforementioned performance indicators using corresponding weight values ​​yields a comprehensive evaluation index for the grinding media evaluation model. S :

[0010] (1),

[0011] In the formula: αW , α E , α P , α L These are the weight values ​​corresponding to each performance indicator, and the specific values ​​are determined based on empirical data, historical performance, and the requirements of specific applications.

[0012] C. Grinding Media Prediction: Select the grinding media and obtain the corresponding performance indicators. W , E , P and L Determine the weight values ​​corresponding to each performance index of grinding media. α W , α E , α P , α L The predictive comprehensive evaluation index of grinding media is calculated using Formula 1. S ;

[0013] D. Engineering Evaluation: If the grinding media has not undergone engineering evaluation, then experiments should be conducted on the grinding media to determine the actual performance index. Then, each actual performance index should be substituted into Formula 1 of the above evaluation model to obtain the actual comprehensive evaluation index. S’ Subsequently, the predictive comprehensive evaluation index of grinding media was used. S Compared with the actual comprehensive evaluation index S’ By comparison, the accuracy of the model in evaluating grinding media is evaluated. If the accuracy does not meet the requirements, the performance parameters of the grinding media evaluation model are corrected.

[0014] Furthermore, the wear resistance index in step A... W By measuring the wear rate under different conditions r The wear efficiency index was calculated. E The energy consumption index is calculated based on grinding efficiency. P Based on the energy required for grinding a unit of material, the life index is calculated. L Predict the service life of grinding media using wear models.

[0015] Furthermore, the wear resistance index W :

[0016] (2),

[0017] In the formula: r The wear rate of the grinding media. β The wear resistance coefficient of the grinding media.T This refers to the test time.

[0018] Furthermore, the wear efficiency index E :

[0019] (3),

[0020] In the formula: Δm Indicates in Δt The amount of mineral material ground within a given time. P(t) for Δt The grinding power consumption over time.

[0021] Furthermore, the energy consumption index P :

[0022] (4),

[0023] In the formula: P(t) Indicates at any time t Instantaneous power consumption.

[0024] Furthermore, the lifespan index L :

[0025] (5),

[0026] In the formula: M o The initial mass of the grinding media. M f This is the quality threshold at which the grinding media fails.

[0027] Furthermore, the aforementioned M f The remaining mass when the grinding media is less than 10% of the standard size or when it is directly crushed.

[0028] Furthermore, in step D, if the prediction comprehensive evaluation index of the grinding media... S Compared with the actual comprehensive evaluation index S’ Differences: ( S - S’ ) / S’ ×100% ≤ If the value is ±3%, then the comprehensive evaluation index of grinding media is considered to be... S If the prediction is accurate, otherwise the performance parameters of the grinding media need to be adjusted until the difference is no greater than ±3%.

[0029] Furthermore, in step C, if the calculated S value is greater than a preset threshold, this grinding medium is used; otherwise, the grinding medium is changed and steps A to C are repeated; or if multiple grinding media are calculated... S The value then applies to each grinding media. SValues ​​are compared and selected. S The grinding media with the highest value or S The top few values ​​are selected as preferred grinding media.

[0030] Furthermore, the experimental parameters and weight values ​​of the grinding media in step D are the same as the corresponding parameters and weight values ​​calculated by the grinding media in step C.

[0031] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0032] 1. This invention is based on the wear mechanism of grinding media, and firstly defines the wear resistance index of grinding media. W Wear efficiency index E Energy consumption index P and lifespan index L Then, an evaluation model is built on this basis. Subsequently, the comprehensive evaluation index of the selected grinding media is calculated through the evaluation model, and the grinding media is evaluated in an engineering manner to revise the evaluation model. In this way, by quantifying the comprehensive performance of grinding media, it is possible to objectively compare which material or design is more suitable for specific grinding needs, reduce the blindness of human selection, and provide a scientific and accurate basis for the selection and subsequent optimization of grinding media. Moreover, it can be used to monitor the performance changes of grinding media in real time, and the grinding process can be optimized by adjusting the grinding parameters in a timely manner.

[0033] 2. This invention has a wear resistance index W Wear efficiency index E Energy consumption index P and lifespan index L Based on this, construct a comprehensive evaluation index. S As an evaluation model, it not only eliminates the need for complex training processes compared to neural network-based evaluation models, but also eliminates the need for high-intensity computation.

[0034] 3. This invention improves the accuracy of the evaluation model by performing engineering evaluations on selected grinding media according to the evaluation model and then revising the evaluation model.

[0035] 4. The evaluation model of this invention can evaluate the feasibility of applying different grinding media to various specific grinding processes by specifically adjusting the performance index parameters of the grinding media and the weight values ​​in the comprehensive evaluation index, thus having strong adaptability and guidance.

[0036] In summary, this invention has the advantages of low computational cost, objective and accurate evaluation results, and strong guidance. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the process of the present invention. Detailed Implementation

[0038] The present invention will be further described below with reference to the accompanying drawings and embodiments, but this does not limit the present invention in any way. Any changes or substitutions made based on the teachings of the present invention shall fall within the protection scope of the present invention.

[0039] like Figure 1 As shown, this invention includes steps such as defining performance indicators, constructing an evaluation model, predicting grinding media, and engineering evaluation, specifically including:

[0040] A. Define performance indicators: Define the wear resistance index of grinding media. W Wear efficiency index E Energy consumption index P and lifespan index L ;

[0041] B. Constructing the evaluation model: Weighting the aforementioned performance indicators using corresponding weight values ​​yields a comprehensive evaluation index for the grinding media evaluation model. S :

[0042] (1),

[0043] In the formula: α W , α E , α P , α L These are the weight values ​​corresponding to each performance indicator, and the specific values ​​are determined based on empirical data, historical performance, and the requirements of specific applications.

[0044] C. Grinding Media Prediction: Select the grinding media and obtain the corresponding performance indicators. W , E , P and L Determine the weight values ​​corresponding to each performance index of grinding media. α W , α E , α P , α L The predictive comprehensive evaluation index of grinding media is calculated using Formula 1. S ;

[0045] D. Engineering Evaluation: If the grinding media has not undergone engineering evaluation, then experiments should be conducted on the grinding media to determine the actual performance index. Then, each actual performance index should be substituted into Formula 1 of the above evaluation model to obtain the actual comprehensive evaluation index. S’Subsequently, the predictive comprehensive evaluation index of grinding media was used. S Compared with the actual comprehensive evaluation index S’ By comparison, the accuracy of the model in evaluating grinding media is evaluated. If the accuracy does not meet the requirements, the performance parameters of the grinding media evaluation model are corrected.

[0046] The wear resistance index in step A W By measuring the wear rate under different conditions r The wear efficiency index was calculated. E The energy consumption index is calculated based on grinding efficiency. P Based on the energy required for grinding a unit of material, the life index is calculated. L Predict the service life of grinding media using wear models.

[0047] The wear resistance index W :

[0048] (2),

[0049] In the formula: r The wear rate of the grinding media. β The wear resistance coefficient of the grinding media. T This refers to the test time.

[0050] The wear efficiency index E :

[0051] (3),

[0052] In the formula: Δm Indicates in Δt The amount of mineral material ground within a given time (i.e., grinding efficiency). P(t) for Δt The grinding power consumption (i.e., energy consumption) over time.

[0053] The energy consumption index P :

[0054] (4),

[0055] In the formula: P(t) Indicates at any time t Instantaneous power consumption.

[0056] The lifespan index L :

[0057] (5),

[0058] In the formula: M o The initial mass of the grinding media. Mf This is the quality threshold at which the grinding media fails.

[0059] The M f The remaining mass when the grinding media is less than 10% of the standard size or when it is directly crushed.

[0060] In step D, if the comprehensive evaluation index of the grinding media is predicted... S Compared with the actual comprehensive evaluation index S’ Differences: ( S - S’ ) / S’ ×100% ≤ If the value is ±3%, then the comprehensive evaluation index of grinding media is considered to be... S If the prediction is accurate, otherwise the performance parameters of the grinding media need to be adjusted until the difference is no greater than ±3%.

[0061] In step C, if the calculated S value is greater than a preset threshold, this grinding medium is used; otherwise, the grinding medium is changed and steps A to C are repeated. Alternatively, if multiple grinding media are available for calculation... S The value then applies to each grinding media. S Values ​​are compared and selected. S The grinding media with the highest value or S The top few values ​​are selected as preferred grinding media.

[0062] The experimental parameters and weight values ​​of the grinding media in step D are the same as the corresponding parameters and weight values ​​calculated by the grinding media in step C.

[0063] Example 1

[0064] The performance of high-carbon steel balls, ceramic balls, polyurethane balls, and cemented carbide balls was evaluated under the same grinding mill and similar operating conditions. The specific process is as follows:

[0065] S100 defines the wear resistance index of grinding media. W Wear efficiency index E Energy consumption index P and lifespan index L .

[0066] S110, the wear resistance index W :

[0067] (2),

[0068] In the formula: r The wear rate of the grinding media. β The wear resistance coefficient of the grinding media. T This refers to the test time.

[0069] S120, the wear efficiency indexE :

[0070] (3),

[0071] In the formula: Δm Indicates in Δt The amount of mineral material ground within a given time (i.e., grinding efficiency). P(t) for Δt The grinding power consumption (i.e., energy consumption) over time.

[0072] S130, the energy consumption index P :

[0073] (4),

[0074] In the formula: P(t) Indicates at any time t Instantaneous power consumption.

[0075] S140, the lifespan index L :

[0076] (5),

[0077] In the formula: M o The initial mass of the grinding media. M f The mass threshold when grinding media fail ( M f The remaining mass when the grinding media is less than 10% of the standard size or when crushing occurs directly.

[0078] S200. Using weight values, the aforementioned performance indicators are weighted accordingly to obtain the comprehensive evaluation index of the grinding media evaluation model. S :

[0079] (1),

[0080] In the formula: α W , α E , α P , α L These are the weight values ​​corresponding to each performance indicator, and the specific values ​​are determined based on empirical data, historical performance, and the requirements of specific applications.

[0081] S300. High-carbon steel balls, ceramic balls, polyurethane balls, and cemented carbide balls were selected as grinding media, and the performance indicators of each grinding media were obtained. W , E ,P and L Determine the weight values ​​corresponding to each performance index of each grinding media. α W , α E , α P , α L The predictive comprehensive evaluation index of each grinding media was calculated using Formula 1. S Then, for each grinding media S Values ​​are compared and selected. S The grinding media with the highest value or S The top few values ​​are selected as preferred grinding media.

[0082] Table 1 Wear resistance data of grinding media

[0083]

[0084] S400. If the grinding media has not undergone engineering evaluation, then conduct experiments on the grinding media.

[0085] S410, Experimental Design.

[0086] S411. Media preparation: Prepare sufficient quantities of high-carbon steel balls, ceramic balls, polyurethane balls, and hard alloy balls, ensuring consistency in size and weight for each type of media.

[0087] S412. Grinding experiment: In a standard grinding mill, a grinding experiment is conducted on the same mineral using each type of media. The operating conditions for each experiment are recorded, such as grinding time, mill speed, and grinding media filling amount.

[0088] S413. Performance testing: Perform wear resistance testing, wear efficiency testing, energy consumption measurement, and life prediction for each medium.

[0089] S420, Experimental Data and Processing.

[0090] S421. After completing the experiment, collect and organize the following data for further analysis and model validation.

[0091] Table 2 Key Data of Grinding Media

[0092]

[0093] S422. Data processing includes: calculating the wear rate of each medium based on the initial and final mass; calculating the grinding efficiency of each medium, i.e., the amount of material ground per unit time; and calculating energy consumption based on the operating time and energy consumption records for each medium.

[0094] S430, Experimental Results.

[0095] Substitute the data collected in Table 2 into formulas 1 to 5 of the evaluation model to calculate the actual comprehensive evaluation index for each medium. S’ The calculation results are shown in Table 3.

[0096] Table 3 Evaluation Results

[0097]

[0098] S440, Model Validation and Analysis.

[0099] To verify the accuracy of the model, it is necessary to compare the model's overall predictive evaluation index. S Compared with the actual comprehensive evaluation index S’ This comparison will be based on the calculated comprehensive evaluation index and the actual comprehensive evaluation index obtained from the experiment. S’ .

[0100] Table 4 Comparison of Predictions and Actual Results

[0101]

[0102] As can be seen from Table 4, the comprehensive evaluation index for prediction of all media... S Compared with the actual comprehensive evaluation index S’ The differences were all within ±3%, indicating that the model has high predictive accuracy. This high accuracy is mainly attributed to the fact that the evaluation model fully considered various key performance indicators of grinding media, such as wear resistance, grinding efficiency, energy consumption, and lifespan, when it was constructed.

[0103] Among them, cemented carbide balls showed the smallest difference between prediction and reality, which may be because the performance of cemented carbide is relatively stable and predictable in grinding media. In contrast, polyurethane balls showed a slight negative difference, indicating that the actual performance was slightly better than the model prediction, possibly because some advantages of polyurethane balls in actual operation were not fully reflected in the model.

[0104] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for evaluating the performance of grinding media based on wear mechanisms, characterized in that... This includes defining performance indicators, building evaluation models, predicting grinding media, and engineering evaluation steps, specifically including: A. Define performance indicators: Define the wear resistance index of grinding media. W Wear efficiency index E Energy consumption index P and lifespan index L ; Abrasion resistance index W By measuring the wear rate under different conditions r The wear efficiency index was calculated. E The energy consumption index is calculated based on grinding efficiency. P Based on the energy required for grinding a unit of material, the life index is calculated. L Predict the service life of grinding media using wear models; The wear resistance index W : （2）， In Equation 2: r The wear rate of the grinding media. β The wear resistance coefficient of the grinding media. T For testing time; The wear efficiency index E : （3）， In Equation 3: Δm Indicates in Δt The amount of mineral material ground within a given time. P(t) for Δt Grinding power consumption over time; The energy consumption index P : （4）， In Equation 4: P(t) Indicates at any time t Instantaneous power consumption; The lifespan index L : （5）， In Equation 5: M o The initial mass of the grinding media. M f This is the mass threshold at which the grinding media fails; B. Constructing the evaluation model: Weighting the aforementioned performance indicators using corresponding weight values ​​yields a comprehensive evaluation index for the grinding media evaluation model. S : （1）， In Equation 1: α W , α E , α P , α L These are the weight values ​​corresponding to each performance indicator, and the specific values ​​are determined based on empirical data, historical performance, and the requirements of specific applications. C. Grinding Media Prediction: Select the grinding media and obtain the corresponding performance indicators. W , E , P and L Determine the weight values ​​corresponding to each performance index of grinding media. α W , α E , α P , α L The predictive comprehensive evaluation index of grinding media is calculated using Formula 1. S ; D. Engineering Evaluation: If the grinding media has not undergone engineering evaluation, then experiments should be conducted on the grinding media to determine the actual performance index. Then, each actual performance index should be substituted into Formula 1 of the above evaluation model to obtain the actual comprehensive evaluation index. S’ Subsequently, the predictive comprehensive evaluation index of grinding media was used. S Compared with the actual comprehensive evaluation index S’ By comparison, the accuracy of the model in evaluating grinding media is evaluated. If the accuracy does not meet the requirements, the performance parameters of the grinding media evaluation model are corrected.

2. The grinding media performance evaluation method based on wear mechanism according to claim 1, characterized in that... The M f The remaining mass when the grinding media is less than 10% of the standard size or when it is directly crushed.

3. The grinding media performance evaluation method based on wear mechanism according to claim 1 or 2, characterized in that... In step D, if the comprehensive evaluation index of the grinding media is predicted... S Compared with the actual comprehensive evaluation index S’ Differences: ( S-S' ) / S’ ×100% ≤ If the value is ±3%, then the comprehensive evaluation index of grinding media is considered to be... S If the prediction is accurate, otherwise the performance parameters of the grinding media need to be adjusted until the difference is no greater than ±3%.

4. The grinding media performance evaluation method based on wear mechanism according to claim 3, characterized in that... In step C, if the calculated S value is greater than a preset threshold, this grinding medium is used; otherwise, the grinding medium is changed and steps A to C are repeated. Alternatively, if multiple grinding media are available for calculation... S The value then applies to each grinding media. S Values ​​are compared and selected. S It is the grinding media with the highest value.

5. The grinding media performance evaluation method based on wear mechanism according to claim 3, characterized in that... The experimental parameters and weight values ​​of the grinding media in step D are the same as the corresponding parameters and weight values ​​calculated by the grinding media in step C.

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