Composite Grinding Mill Shell Plate for Wear-Resistant Retreatment
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Solution Overview
Problem
Existing grinding mill shell plates face wear issues due to the grinding process, necessitating frequent replacement and high maintenance costs, and there is a need for materials that can withstand the abrasive environment while reducing energy consumption in manufacturing.
Innovation Solution
The shell plates are composed of a combination of polyurethane and rubber, with the wear surface made of polyurethane and the fixing surface made of rubber or recycled rubber, allowing for easier manufacturing and retreatment when the wear surface is worn out, and the use of lifter bars to lift and crush material within the grinding mill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-material shell plates are used, then manufacturing is simpler, but wear resistance is insufficient leading to frequent replacement
Solution Approach 1:
The shell plate is constructed as a composite structure with a polyurethane wear layer (5-20mm thick) bonded to a rubber or recycled rubber base. This composite design provides superior wear resistance in the polyurethane layer while the rubber base offers flexibility and shock absorption, resolving the contradiction between wear resistance and manufacturing simplicity.
Solution Approach 2:
Different regions of the shell plate are made from different materials optimized for their specific functions: the polyurethane material is used where wear resistance is critical (facing the grinding media), while the rubber base provides structural support and flexibility. This local differentiation of material properties achieves high wear resistance without requiring the entire structure to be complex.
2Duration of action of stationary object
If high durability materials are used, then maintenance frequency decreases, but manufacturing energy consumption increases
Solution Approach 1:
The shell plate is segmented into two functional layers that can be manufactured separately and then bonded together. The polyurethane wear layer can be produced independently and attached to the rubber base, allowing for optimized manufacturing processes for each material and reducing overall energy consumption while maintaining high durability.
Solution Approach 2:
The invention changes the material parameters by using polyurethane with specific thickness (5-20mm) and bonding it to a rubber base, creating a composite structure that achieves high service life through material selection and configuration rather than through energy-intensive manufacturing processes.
3Reliability
If the wear surface is made of highly durable material, then replacement frequency decreases, but retreatment capability is reduced
Solution Approach 1:
The shell plate is divided into a replaceable polyurethane wear layer and a permanent rubber base. When the polyurethane layer becomes worn, it can be removed and replaced with a new layer while the rubber base remains in place. This segmentation enables easy retreatment and extension of the shell plate's service life without requiring complete replacement.
Solution Approach 2:
The polyurethane wear layer is designed to be discarded when worn out, while the rubber base is recovered and reused. This allows for cost-effective retreatment by replacing only the consumable wear layer while retaining the structural base, improving ease of repair while maintaining high wear resistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The polyurethane-rubber composite shell plates provide enhanced wear resistance, reducing maintenance frequency and energy consumption, while allowing for on-site retreatment, thus lowering operational costs and improving durability.
Implementation Method 1
The polyurethane-rubber composite shell plates provide enhanced wear resistance, reducing maintenance frequency and energy consumption
Data Source
Figure 1~2
Figure 3
Figure 4a~4c
AI summary
The invention relates to a shell plate (1), to method for making a shell plate (1) and to a grinding mill (3) for ore grinding. The shell plate (1) is mountable to a shell (2) of a grinding mill (3) for grinding ore, said shell plate (1) comprises a shell plate body (10) having a first portion (10a) comprising a fixing surface (13) for fixing the shell plate body (10) to the shell (2) and a second portion (10b) comprising a wear surface (12) facing toward interior of the grinding mill (3), said first portion (10a) and said second portion (10b) forming a continuous shell plate body (10), the second portion (10b) comprises polyurethane such that the wear surface (12) is made of polyurethane.