Wear Characteristics of Large Grinding Balls in an SAG Mill

Abstract

The wear characteristics of larger than 120 mm-diameter grinding balls used in large semiautogenous (SAG) mills is studied in the present paper. SEM observation on the worn ball surface reveals a severe microcutting process. Abrasion grooves can be found on the overall surface. Moreover, persistent microcracks are found on the surface. The observation on the cross section indicates extended white layers and white bands exist in the subsurface of worn balls. The white layer is not homogenous on the surface. The largest white layer is about 20 μm thick and 1.3 mm long. The wear resistance of the white layer is tested with a simulated high stress impact wear tester. It is found that the white layer is associated with delamination wear, which significantly increases the wear rate. The delamination wear mechanism is explained from the intensely deformed microstructure and microcracks inside the white layer. Based on the experimental results, a wear formula consisting of both microcutting wear and delamination wear is submitted. This formula means that high wear resistance is only achieved when the hardness and fracture toughness of grinding balls are increased simultaneously.

Presented at the 52nd Annual Meeting in Kansas City, Missouri May 18–22, 1997

KEY WORDS:

• Wear Mechanisms
• Grinding
• Wear

Notes

Presented at the 52nd Annual Meeting in Kansas City, Missouri May 18–22, 1997