Kalhankov Ye., Lysytsia М., Kromik A., Ahaltsov H., Novikova А., Tolstenko О. Determination of rubber lining thickness with accounting dissipative losses and viscoelastic response
- Details
- Parent Category: Geo-Technical Mechanics, 2025
- Category: Geo-Technical Mechanics, 2025, Issue 175
Geotech. meh. 2025, 175, 101-112
https://doi.org/10.15407/geotm2025.175.101
DETERMINATION OF RUBBER LINING THICKNESS WITH ACCOUNTING DISSIPATIVE LOSSES AND VISCOELASTIC RESPONSE
2Kromik A.
1M.S. Poliakov Institute of Geotechnical Mechanics of the National Academy of Sciences of Ukraine
2ALUMATEC GmbH Germany
3Dnipro State Agrarian and Economic University
UDC 621.928:678.7:539.4:620.178.16
Language: English
Abstract. The article is devoted to the engineering-based selection of the rubber lining thickness used in ball mills with accounting dissipative losses and the viscoelastic response of the material. It is shown that empirical schemes including DEM models require significant calibration, whereas for design, a concise and physically interpreted methodology is needed at the stage of preliminary selection of the plate thickness. Herein, an approach is proposed in which the energy of the ball impact (equivalent drop height) is balanced by the energy of the rubber plate deformation, and the effect of the finite thickness and near-incompressibility of the rubber is considered through effective stiffness and transverse "splashing" of the layer. The ratios for the maximum local deformation and the performance criterion ε=δmax/t≤εall. are derived, which allow a straightforward determination of the minimum required plate thickness for given energy and kinematic conditions of the first stage of grinding (ball diameter 100–125 mm).
For validation of the proposed methodology, experimental tests were performed by dropping a steel ball with a diameter of 100 mm onto rubber specimens of 50–270 mm thickness. The test series revealed a trend of monotonic increase in the diameter of the indentation and contact parameters with increasing drop height, as well as a pronounced thickness effect: under constant load, an increase in t reduces peak pressures by 15–28% and maximum forces by 11–20%, which is consistent with the expected relaxation of the stress state of the surface layer. Regression 3D response surfaces Pmax(t,H), p0(t,H) were constructed for interpolation within the experimental range and for mapping of “safe zones” of operation without additional tests.
The practical recommendations are supplemented with constructive conclusions: the trapezoidal “plate-H-wave” configuration rapidly acquires optimal morphometric parameters within the first weeks of operation and contributes to productivity growth by 10–15%, a reduction in the specific consumption of balls by 15–20%, an increase in the yield of the finished product by 3–7% and a decrease in specific energy consumption by 5–10%. The proposed methodology is a reproducible engineering tool for preliminary calculation of thickness with its further refinement for a specific mill, mode and ore type, complementing DEM and empirical approaches and shortening the “design-test-implementation” cycle.
Keywords. mill, lining thickness, dissipation, deformation, durability, rubber lining, modeling, wear.
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About the authors
Kalhankov Yevhen, Engineer in Department of Elastomeric Component Mechanics in Mining Machines, M.S. Poliakov Institute of Geotechnical Mechanics of the National Academy of Sciences of Ukraine, Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it. , ORCID 0000-0002-4759-6687
Lysytsia Mykola, Candidate of Technical Sciences (Ph.D.), Senior Researcher, Senior Researcher in Department of Elastomeric Component Mechanics in Mining Machines, M.S. Poliakov Institute of Geotechnical Mechanics of the National Academy of Sciences ofUkraine, Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it. (Corresponding author), ORCID 0000-0001-6364-8937
Kromik Andreas, Chief Designer at ALUMATEC GmbH, Kaarst, Germany, This email address is being protected from spambots. You need JavaScript enabled to view it.
Ahaltsov Hennadii, Master of Science, Junior Researcher of Department of Elastomeric Component Mechanics in Mining Machines, M.S. Poliakov Institute of Geotechnical Mechanics of the National Academy of Sciences ofUkraine, Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it. , ORCID 0000-0001-6296-7573
Novikova Alina, Junior Researcher of Department of Elastomeric Component Mechanics in Mining Machines, M.S. Poliakov Institute of Geotechnical Mechanics of the National Academy of Sciences ofUkraine, Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it. , ORCID 0000-0002-4861-0196
Tolstenko Oleksandr, Candidate of Technical Sciences (Ph.D.), Associate Professor of the Department of Engineering of Technical Systems, Dnipro State Agrarian and Economic University (DSAEU), Dnipro, Ukraine, This email address is being protected from spambots. You need JavaScript enabled to view it. , ORCID 0000-0003-4752-5704