Accepted Manuscript

Title: Wear characterization and modeling of Mn-steel liners

used in rock crushers

Author: Rahul Sinha A.K. Mukhopadhyay

PII: S2213-0209(16)30101-X
DOI: http://dx.doi.org/doi:10.1016/j.pisc.2016.04.079
Reference: PISC 249

To appear in:

Received date: 1-2-2016

Accepted date: 11-4-2016

Please cite this article as: Sinha, R., Mukhopadhyay, A.K.,Wear characterization and
modeling of Mn-steel liners used in rock crushers, Perspectives in Science (2016),
http://dx.doi.org/10.1016/j.pisc.2016.04.079

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Wear characterization and modeling of Mn-steel liners used in rock crushers

Rahul Sinha1, A. K. Mukhopadhyay1

1
Dept. of Mining Machinery Engineering, Indian school of mines, Dhanbad
Phone no.: +91-9608501005, e-mail: sinharahul30@gmail.com

Abstract

There are several techniques such as surface profilometry, advanced technique of electron microscpopy and

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optical methods which have been used by researchers to determine the measurement of wear and it is found
useful to understand the surface geometry of the material. In mining industries, wear is acute in rock crusher.

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This work explores the characterization of wear observed on the surface of liner material of roll crusher
crushing coal. Wear characterization like ploughing, scratching, cavities has been observed on the surface of

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liners. To correlate wear characterization due to abrasion on roll crusher liner wear, experiments have been
performed. To perform abrasive wear test, pin shaped sample of liner material has been developed for the

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purpose of testing. The abrasive wear experiment was conducted using pin-on-disc tribometer. During the
investigation, experiments based on full factorial design adopted from statistical modeling software. In this
methodology the input parameters like load, sliding distance, hardness of coal, hardness of liner material are
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taken into consideration, and weight loss was considered as the output response. The influence of each input
parameters were examined to understand its effect for weight loss. The regression equation obtained from
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analysis of variance table was used for the prediction of weight loss. The regression equation developed was
validated with the experimental results. The percentage error was observed less than ±10%.
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Keywords: Abrasive wear, Pin-on-disc, ANOVA, FESEM.

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Introduction
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Hadfield steel has emerged as the most effective material to use against wear and tear damage due to its great
properties. The wear resistant property of Hadfield steel material stands on two theories: first relates to dipole
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interaction of C-Mn and second theory is related to stacking fault energy (SFE) (Desch and Hadfield, 1941).
Thus due to the property of dipole interaction and SFE, use of Hadfield steel in many industries proved
beneficial. But wear as a challenge is still uncertain in most of the industries, mining industry is one of them.
The change in surface geometry due to abrasion can be recognized by some recent advanced technique such
as atomic force microscope, scanning electron microscope, optical microscope etc (Hase et al., 2014). The
change in surface geometry may occur due to insufficient loading condition, type of surface contact between
the contacting medium, surface hardness etc. Hokkirigawa and Kato (1938) used acoustic emission technique
used to elucidate wear characterization using scanning electron microscope. Wang and kato (2000)
performed microscopic level of investigation to find the effect of spherical diamond shape in material loss
due to wear. They performed experiments to explore wear characterization using statistical methodology to
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identify the effective parameter for wear. Mahapatra and Patnaik (2009) used Taguchi design of experiment
to minimize wear rate. They performed erosive wear experiments followed by study of worn surface area in
scanning electron microscopy. Kumar et al. (2013) performed abrasive wear experiments using pin-on-disc
set-up to identify effects of control factors in weight loss of material. Their abrasive wear experiment to
determine weight loss was carried out using full factorial design. Using full factorial design the effects of
each control factor was judged using analysis of variance (ANOVA). Similar work was performed to develop
mathematical model using regression analysis for the prediction of wear. The adequacy of the developed

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model was tested using ANOVA (Mandal et al., 2012).

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The present study is performed on Mn-steel liner material of roll crusher having two hardness values of 220

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BHN and 350 BHN. The worn surface of liner was first investigated using field emission scanning electron
microscope (FESEM). From the two collected hardness values of liner, 15 pins in pair have been fabricated

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into ϕ12 mm × 30 mm shape. The pins were made to slide on the surface of metallic disc with layers of coal
pasted on it. For sliding abrasion, 15 metallic discs in pair were prepared with coal of hardness values of 4.5

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mohs and 5.5 mohs. The abrasive wear test was performed using pin-on-disc abrasive wear experiment set-up
to correlate the loss of material from liner surface during abrasive sliding of coal particles. The test was
performed using full factorial design as adopted from statistical methodology. Investigations using abrasive
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wear experiment were done to identify the effect of wear parameters on weight loss using analysis of
variance (ANOVA). The selected wear parameters for the abrasive wear tests are load, sliding distance,
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hardness of coal and hardness of liner material. Using ANOVA regression equation was developed for wear
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prediction which was further validated with 5 abrasive wear test runs. The worn surface of pin material after
abrasive wear test was investigated using FESEM to compare the results of microphotographs obtained for
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liner material.
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2. Statistical Methodology

Statistical methodology is a statistical design tool which is broadly accepted for wear analysis. This statistical
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tool has found out to be more suitable for analysing the effect of input parameter on weight loss. The
statistical modeling was performed using full factorial design, a sub branch of statistical tool. The wear
parameters taken for full factorial design are load, sliding distance, hardness of coal and hardness of liner
material. For each input wear parameters two levels have been selected such as low (–) and high (+). The low
and high levels values of load are 5 N and 35 N respectively. For sliding distance it is 1000 m (–) and 2000 m
(+). Selected values of hardness of coal are 4.5 mohs for low level and 5.5 mohs for high level. The low and
high levels for hardness of liner material are 220 BHN and 350 BHN respectively. The generated abrasive
wear experiment was conducted using 24 factorial relations. Thus, sixteen number of abrasive wear
experiments have been conducted as shown in Table 1. The aim of this study is to model the effects of input
parameter on weight loss of material.
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Table 1
Experiment data for abrasive wear test using full factorial design
Levels for input parameter Output response
Load Sliding distance Hardness of coal Hardness of liner Weight loss (gm)

– + – – 0.0011
– + + + 0.0034
+ – – + 0.0016
+ + + + 0.0031

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– – + – 0.0007

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– + – + 0.0015
+ + – + 0.0039
+ + – – 0.0045

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– + + – 0.0009
+ – + – 0.0042
+ – + + 0.0024

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– – – – 0.0021
+ – – – 0.0026
– – + + 0.0003

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+ + + – 0.0056
– – – + 0.0005
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2.1 Results and discussions
2.1.1 Analysis of variance, Regression analysis and result validation
The outcome results of experiment were analyzed with the help of ANOVA. With the help of ANOVA the
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percentage contribution of each wear parameters on weight loss can be easily estimated. The contribution of
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each wear parameters has been noted at 5% (p = 0.05) level of significance. If the p-value for a parameter is
less than 0.05 then it has statistically significant contribution in weight loss. From ANOVA table of weight
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loss (Table 2), the obtained result of p-value for load, sliding distance and interaction of load with hardness
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of liner material is less than 0.05. Thus, these factors play a major role in weight loss as compared to the
others whose obtained p-value is more than 0.05. The obtained value of R-squared is 0.9934 with adjusted R-
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squared as 0.9502.
The parameters which are found to be insignificant from the ANOVA table are considered for regression
equation. The obtained regression equation for weight loss prediction is stated below as:

Weight loss = 0.01892 + (0.000227×10–3×load) + (0.0001217×10–3×sliding distance) – (0.00953×10–

3
×load×hardness of liner)

The developed regression equation was then validated with number of test results as shown in Table 2. From
the validated results of regression equation it has been noted that the percentage error obtained is less than
±10%.

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Table 2
ANOVA table and validation of regression equation using ANOVA.
Source p-value
Load (N) 0.0066
Sliding distance (m) 0.0212
Hardness of coal (mohs) 0.1876
Hardness of liner (BHN) 0.0722
Load (N) × Sliding distance (m) 0.1692
Load (N) × Hardness of coal (mohs) 0.1876
Load (N) × Hardness of liner (BHN) 0.0410

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Sliding distance (m) × Hardness of coal (mohs) 0.4874
Sliding distance (m) × Hardness of liner (BHN) 0.0837
Hardness of coal (mohs) × Hardness of liner ( BHN) 0.7140

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Validation of regression equation using ANOVA

Load Sliding distance Hardness of liner Weight loss %Error

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Measured Predicted
12 1000 220 0.0006 0.00066 –10
18 1500 350 0.0390 0.04093 –4.94

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25 2000 220 0.0340 0.03324 2.235
12 2000 350 0.0200 0.02085 –4.25
25 1500 220 0.0310 0.03331 –7.45
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2.2.3 Wear Characterization
Due to the action of plowing, micro-cutting/ micro-scratch and fragmentation of cracked surface layers
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abrasive wear occurs (Tiwari et al., 2002; Hase et al., 2012). FESEM was employed to observe the type of
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wear mechanism on the surface of liner and fabricated pin material. The microphotographs obtained for worn
out surface of roll crusher liner material is shown in figure 1 (a) and figure 1(b). Also, microphotographs
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obtained for the worn surface of fabricated pin materials are shown in figure 1(c) and figure 1(d). In figure
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1(a) the obtained wear mechanisms are grooves and micro-cracks. For figure 1(b) the obtained results of
wear mechanism is plowing and micro-scratch. Similar wear mechanisms has been resulted for pin material
as compare to the results of liner material for microphotographs shown in figure 1(c) and figure 1(d) except
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material removal due to plowing.

3. Conclusions
The significance effect of load, sliding distance and interaction of load with hardness of liner is of great
influence for application in abrasive wear. In present statistical analysis, abrasive wear experiments have
been performed using full factorial design. Under applied conditions the wear observation was coupled with
the relationship the measured result as weight loss. The abrasive wear properties of liner material well
exhibited by full factorial design to know the effect of wear parameters on output response as weight loss.
From the ANOVA table the regression equation was calculated to observe the significance of each input
parameters. It has been observed that load has maximum effect with minimum p value (=0.0066) as
compared to the interaction of load with hardness of liner having p value as 0.0410. The adequacy
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model was checked to confirm the test result with predicted regression equation with an accuracy of ±10%.
The worn out surface has been checked using FESEM for wear characterization. It has been observed that
plowing, micro-scratch, grooves and micro-cracks type of abrasive wear observed on the surface of liner.

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Figure 1: FESEM microphotographs of worn surface (a) grooves and micro-cracks obtained for liner material; (b) micro-scratch
and plowing obtained for liner material; (c) grooves and micro-cracks obtained for Mn-steel pin material; and (d) micro-scratch
obtained for Mn-steel pin material.
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