BASICS WEAR MATERIALS SAL ES MANUAL

RELEASE DATE: 3-12-03

BASICS
WHY USE MANGANESE.........................................................................................................2-2
ROCK DIMENSIONS................................................................................................................2-3
ROCK TESTS ............................................................................................................................2-4
TYPES OF WEAR .................................................................................................................. 2-11

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BASICS WEAR MATERIALS SAL ES MANUAL

RELEASE DATE: 3-12-03

WHY USE MANGANESE

 Primarily for toughness.

 The ability to withstand severe impact without fracturing.

 Absorbs huge amounts of energy and undergoes extensive plastic deformation

without cracking.

 Manganese steel has good abrasion resistance.

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RELEASE DATE: 3-12-03

ROCK DIMENSIONS
Typical "standard" ratios of rock dimensions

b = width
a = .6 b (thickness)
c = 1.6 b (length)

The illustration; Rock Dimensions below will provide you with a key to the respective
values.

ROCK DIMENSIONS

So if the average width (b) of a rock is 6", the thickness (a) would be 3.6", and the
length (c) would be 9.6".

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ROCK TESTS
The following rock tests are most commonly referred to when discussing application and
wear materials.

Chemical Analysis :
The chemical analysis is typically run to determine the suitability for Impact Crusher
applications.

1. A five (5) pound sample of stone is required.

2. Sample is chemically analyzed for the percentages of;

Calcium Carbonate
Silica
Metallic Oxides including Aluminum Oxide Iron and all Iron Oxides.
Magnesium Carbonate

3. Silica Equivalent = 2(Al2O3 +Total Fe)+SiO2+MgO

4. For Primary Impact Crushers, the silica equivalent should be under 0.15%.

5. For Secondary Impact Crushers, the silica equivalent should be under 0.05%.

6. If more than 5% magnesium carbonate or other abrasive elements are present, back
up tests such as a Paddle Abrasion test should be performed.

Compressive Strength:
1. Samples required are two - 2" diameter by 2" long specimens taken from the same
rock 90 degrees to one another.

2. The cylinder of rock is placed between a special bearing block and the head of a
suitable testing machine.

3. The specimen is put under pressure until it fails at which time the pressure (PSI)
required to fail is recorded.

4. Unit crushing strength is calculated in pounds per square inches.

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BOND WORK INDEX (IMPACT WORK INDEX)

Main Principle:
The purpose of this impact test is to establish a Bond Work Index (Impact Work
Index). The Work Index can be used for estimating crushability of material and
energy consumption of crusher.

Material:
For the Work index test at least 10 representative rocks are required. They must
have cubical shape and they must pass a 3" screen opening but retained on a 2"
opening. The ideal sample has two parallel or near parallel sides.

The sharp edges of sample can be slightly rounded (by hand hammer) before the
test.

Test Procedure:
The rocks are tested individually. A rock is placed on the test pedestal in such a
manner as to allow the hammers to strike perpendicular to the parallel surfaces. The
thickness of the sample is measured by a caliper rule. This dimension is the same
than the distance between the hammers when they strike against the rock.

The hammers are raised to an appropriate height and released simultaneously. Then
the rock is checked to assure it is still sound and returned to the test pedestal to the
same position as the start of the test. The hammers are raised to the next highest
position and released simultaneously. The drop height is increased until the rock
breaks.

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The purpose of this impact test is to establish a Bond Work Index (Impact Work
Index). The Work Index can be used for estimating crushability of material and
energy consumption of crusher.

Result Calculation:

WI = 67,8 x H / (C x G) [kWh/t]

WI = Impact Work Index (Bond Work Index) [kWh/t]

H = the drop height when the stone breaks (reading from
measuring scale)
C = the thickness of the sample [mm]
G = specific gravity [g/cm3]

The final WI is average of all rocks tested.

LOS ANGELES TEST

Main Principle:
The purpose of this test is to establish a Los Angeles value. Los Angeles value gives an
indication of the resistance of material to abrasion and impact.

Los Angeles test (in Nordberg-Lokomo) is based on ASTM -standard C131 - 89 “

Resistance to Degradation of Small-Size Coarse Aggregate b y Ab rasion and Impact in
t
heLosAngel esmachi ne” .

Los Angeles Machine

The Los Angeles testing machine consists of a hollow steel cylinder closed at both ends
having inside diameter of 711 mm and inside length of 510 mm. The machine rotates 30
(- 33) rpm for 500 revolutions.

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On the interior surface of the cylinder there is a steel shelf plate (height 89 mm), which
carries material and steel spheres until they are dropped to the opposite side of the
drum.

To the drum with material is also placed 11 steel spheres which average diameter is 47
mm and each weight between 390 g - 445 g.

Material Preparation:
The material to be tested: 9,52 mm - 12,7 mm 2500 g
12,7 mm - 19 mm 2500 g
___________________________
Total: 5000 g

Test Procedure:
The 5000 g. test sample with the 11 steel spheres is placed into the Los Angeles
machine. The machine rotates 500 revolutions (takes about 16 minutes). After
prescribed number of revolutions the material is emptied from the drum and the tested
material is screened on a 1,68 mm screen. Percentage of material passing through the
screen is Los Angeles value.

Result Calculation:
Los A - value = M -1,68mm / 5000 g * 100 [ %]

M -1,68mm = material from Los Angeles machine which passes a

1,68 mm screen.

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PADDLE ABRASION TEST (ABRASION INDEX)

Main Principle:
The purpose of Abrasion Test is to establish an Abrasion Index. The Abrasion Index
gives an indication of the abrasiveness of the material. Abrasion Index is used for
estimating lifetime of wear parts of crushers.

Paddle Abrasion Tester

The Paddle Abrasion Tester consists of a slotted inner hub, which rotates inside an
outer closed cylinder (horizontally). The hub with a test paddle rotates 678 RPM and
the cylinder 76 RPM. The diameter of the outer cylinder is 305 mm and the diameter
of the inner hub is 110 mm.
In the surface of the cylinder there is 12 small shelf plates. When the drum rotates
these shelf plates picks up material and carrying it until it is dropped and hit against
the test paddle or the bottom of steel drum.

Paddle Preparation:
The paddle for the test: 76 mm x 25 mm x 5 mm
St 52-3 (Fe 52C, 158 HB)

Before the test, the paddle is dressed with a fine file for any burrs and sharp edges.
The cleaned and dry paddle is weighed.

Material:
The material to be tested: 12 - 16 mm 200 g
16 - 19 mm 200 g
_________________________
Total: 12 - 19 mm 400 g x 4 = 1600 g

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The sample for the abrasion test is taken from two times crushed material if possible.

Test Procedure:
The paddle is clamped in the slot of the inner hub. A 400-g sample of material to be
tested is placed in the drum.

The drum and the test paddle rotate for 15 minutes. The paddle rotates to the same
direction than the drum but about nine times faster. After 15 minutes rotation the
drum is emptied and the process is repeated three times so that the paddle is
subjected to wear for an hour.

After an hour rotation the paddle is removed, cleaned and dried. The paddle is
weighed. The weight loss in grams is the Abrasion Index (Ai) of the tested material.

Ai–8mm
The material from the test is screened on a square 8 mm screen opening. The
percentage of material that passes the screen is so called Ai -8mm -index. This
value has a good correlation to the other rock tests and it can be used for estimating
other values when the test sample is so small that only Abrasion test can be
produced.

Result Calculation:

Ai = M before - M after [-]

Ai = Abrasion Index
M before = the mass of the cleaned and dried test
paddle before the abrasion test
M after = the mass of the cleaned and dried test
paddle after the abrasion test

Ai -8mm = M-8mm / M total [%]

Ai -8mm = percent ageofmat erial–8mm af ter
the abrasion test
M -8mm = the mass of material which passes the
8 mm screen opening
M total = the mass of material in the abrasion test
(normally 1600 g)

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SPECIFIC GRAVITY

Main principle :
The purpose of this test is to establish a specific gravity. The specific gravity is the ratio
of the mass of material [g] and the unit volume of material [mm3].

Material:
A sample of 5 Kg. of plus 9,5mm aggregate is washed to remove the dust then dried at
1100 C (2300 F) temperature.

Immerse sample in 150 C (590 F) to 250 C (770 F) water for 24 hours and then weigh
(Value B).

Determine weight of sample water (Value C).

Dry again at 1100 C (2300 F) temperature and weigh (Value A).

Result Calculation:

A
Bulk specific gravity =
B–C

A
Apparent specific gravity =
A- C

Specific Gravity Tester

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TYPES OF WEAR
Whati
swear
ing-“
wearandt
ear
”?

Wearing is non-wanted material loss on a surface by means of several different

mechanisms.

Main types of wearing are;

Adhesive
Fatigue
Abrasive

Ter
minol
ogyi
n“wear
ingsci
ence”i
snotv
eryest
abl
i
shedy
et!

In a crusher cavity wear is abrasive.

Abrasive wear happens always by means of foreign particles.

Subtypes of abrasive wearing are:

Gouging abrasion
Scratching abrasion
Grinding abrasion

Gouging abrasion -
big fractions (=boulders)
are smashing against Scratching abrasion -
liners with high fine fractions are sliding
impact energy along liner

Grinding abrasion -
fine fractions are
grinding liner surface
under pressure

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How liner material loss takes place - gouging abrasion:

Gouging abrasion:
* microfracture
* microcutting
(* fatigue cracks)

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BASICS WEAR MATERIALS SAL ES MANUAL

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How liner material loss takes place - grinding abrasion:

Gr
indi
ngabr
asi
on–mi
crocut
ti
ng

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How liner material loss takes place - scratching abrasion:

Main factors in abrasive wearing:

Wearing particles
velocity, size = kinetic energy
material properties
hardness, toughness

Liner material
material properties
hardness, toughness, impact strength, work hardening effect

Environment
humidity, temperature

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Wear resistant material characteristics:

To stop wearing particles to penetrate into liner material

Increase liner hardness

 Good in case of grinding and scratching abrasion.

 BUT usually increasing the hardness in ferrous materials decreases impact strength
and toughness.
 Gouging abrasion resistance decreases.

Increase work hardening and toughness

 Good against gouging abrasion.

 Wear resistance is a compromise between hardness, yield strength and toughness.

Main wearing processes in crushers:

Grinding
Share %

Scratching
Gouging

Primary Secondary Tertiary

Application type

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