Application of artificial neural network method to predict the breakage properties of PGE bearing chromite ore

In the present investigation, systematic grinding experiments were conducted in a laboratory ball mill to determine the breakage properties of low-grade PGE bearing chromite ore. The population balance modeling technique was used to study the breakage parameters such as primary breakage distribution (B_{i, j}) and the specific rates of breakage (S_i). The breakage and selection function values were determined for six feed sizes. The results stated that the breakage follows the first-order grinding kinetics for all the feed sizes. It was observed that the coarser feed sizes exhibit higher selection function values than the finer feed size. Further, an artificial neural network was used to predict breakage characteristics of low-grade PGE bearing chromite ore. The predicted results obtained from the neural network modeling were close to the experimental results with a correlation of determination R² = 0.99 for both product size and selection function.     

Regression analysis of surface roughness and micro-structural study in rotary ultrasonic drilling of BK7

Ceramic materials have tremendous demand in manufacturing sectors. However, poor machinability impedes their widespread applications on an industrial scale. BK-7 falls in the same category and is normally processed by ultrasonic machining. But nowadays rotary ultrasonic machining is overtaking the ultrasonic machining for processing difficult to cut materials because of its superlative material removal mechanism. Current study aims to improve the surface quality of BK7 by studying the effect of input factors on surface roughness during rotary ultrasonic machining. Response surface methodology has been used to observe the effect of input variables ― spindle speed, feed rate and ultrasonic power ― on surface roughness (SR). Thereafter, central composite design was employed to estimate the regression coefficients of quadratic model for surface roughness. Fitness of developed quadratic model was checked by ANOVA test, which also revealed that all the model terms of input factors were significant except feed and speed interaction. Feed has the maximum impact over surface roughness descended by moderate impact of power and spindle speed. The study was further reinforced on observing the surface integrity of processed surfaces using scanning electron microscopic images. Mixed flow of material was observed to occur at lower feed rate and higher levels of rpm and ultrasonic power.     

飞行时间二次离子质谱对矿物表面性质的研究

随着易选矿石的逐步枯竭,低品位、嵌布粒度细等难选矿石的开发利用已成必然趋势。目前,矿物加工已经从实践生产阶段发展到了理论研究指导实践生产的阶段,因此具有分辨率高、信息量大、灵敏快速以及样品用量少等特点的矿物表层研究方法来支撑理论研究是必不可少的。飞行时间二次离子质谱法(TOF-SIMS)是近年来在矿物加工中使用较多的一种矿物表面化学分析方法,具有表面质谱、化学成像、深度剖析、快速灵敏及数据精准的优点,因此总结归纳了近年来TOF-SIMS在矿物加工中应用取得的成果,以期为学者提供可靠的理论依据及技术支持。     

Effect of grinding-induced cyclic heating on the hardened layer generation in the plunge grinding of a cylindrical component

This paper discusses the effects of the grinding-induced cyclic heating on the properties of the hardened layer in a plunge cylindrical grinding process on the high strength steel EN26. It was found that a multi-pass grinding brings about a uniform and continuous hardened layer along the circumference of the cylindrical workpiece. An increase of the number of grinding passes, leads to a thicker layer of hardening, a larger compressive residual stress and a deeper plastic deformation zone. Within the plastic deformation zone, the martensitic grains are refined by the thermo-mechanical loading, giving rise to a hardness of 12.5% higher than that from a conventional martensitic transformation. The coupled effects of heat accumulation and wheel wear in the multi-pass grinding are the main causes for the thickening of the hardened layer. A too small infeed per workpiece revolution would result in insufficient grinding heat, and in turn, bring about an undesirable tempered hardened layer and a reduction of its hardness.     

Assessment of spray quality from an external mix nozzle and its impact on SQL grinding performance

Spray quality is the critical factor which decides the efficacy of Small Quantity Lubrication (SQL) technology in a high specific energy involved machining process like grinding. Yet, the understanding about spray quality, the actual process mechanics and its effect on machining performance is inadequate. The present work is an attempt to establish a correlation between the spray input variables, quality of the spray and machining performance of SQL grinding through modelling and experiments. Using computational fluid dynamic techniques, the variation of droplet size, droplet velocity, number of droplets and heat transfer coefficient have been analysed at different input parameters and the computed trends have been verified and validated. CFD modelling of spray indicates that it is possible to produce aerosol medium with high heat dissipation ability at moderately high air pressure and low flow rate. It also shows that any increase in atomising air pressure favourably leads to notable increase in wetting area and also results in substantial enhancement in heat dissipation ability. Reduction of residual stress is thus remarkably good. On the other hand, grinding fluid flow rate, if increased, offers significantly better lubricity and reduces the grinding force which also reduces tensile residual stress. Short spell grinding test results are found to be in good agreement with CFD results.     

Evaluation of grinding media wear-rate by a combined grinding method

It is well-known that lab tests on wear-rate of grinding media cannot precisely represent its industrial performance due to complex grinding conditions. Nevertheless the lab data provides reference to the industrial data. Therefore, a reproducible test method on wear-rate in lab is necessary.By providing detailed data, this paper challenges the traditional wear-rate testing methods. Two commonly used methods on wear-rate test, self-wear in water and grinding with mineral slurry, are respectively employed. However, obvious fluctuation of wear-rate/time curves indicates neither of the two normal methods is reliable.This paper introduces a wear-rate testing method on lab scale which combines self-wear in water and grinding with mineral slurry. By this method, some repeatable wear-rate/time curves are displayed after a few hours. The mechanism will be discussed in detail in this paper.     

云南某铜矿快速浮选新技术研究

针对云南某铜矿嵌布粒度粗细不均、嵌布关系复杂、部分铜矿物易过磨损失,从而导致铜精矿中铜和伴生金、银回收率低的技术难点,通过采用铜选择性捕收剂BK901G和"铜快速浮选—中矿再磨再选"工艺流程,获得了较好的选矿指标,其中铜精矿中铜的品位和回收率分别达到23.79%和93.66%;伴生金、银的回收率分别达到43.92%和67.93%。该工艺技术可为同类型矿山提供借鉴。     

Comparative study on NiAl and FeAl intermetallic-bonded diamond tools and grinding performance for Si3N4 ceramic

Metal-bonded diamond tools are widely used for machining hard and brittle materials such as ceramic and stone. The metal bonds are normally based on alloys composed of Fe, Co, Ni, Cu, Sn, Zn, or Cr. However, high heavy metal concentrations are hazardous to the environment and tool operators. Furthermore, the high density of these metal bonds results in excessively heavy tools, requiring high energy and intensive labor during operation. Therefore, we propose two environmentally friendly and lightweight metal bonds based on NiAl and FeAl intermetallics for diamond tools by reactive hot-press sintering. The effect of sintering temperature on the microstructure and mechanical properties of NiAl and FeAl was examined and the tribological behavior of NiAl and FeAl on Si₃N₄ ceramic balls was investigated. Grinding performance of the sintered diamond tools on Si₃N₄ ceramic was also compared. Our results reveal that B2-ordered NiAl and FeAl are obtained at sintering temperatures in the range of 700–1100 °C. The relative density of sintered NiAl is higher than that of FeAl, while the Vickers hardness and flexural strength of NiAl are lower than that of FeAl. Compared with FeAl, NiAl demonstrates higher wear resistance in a friction test against Si₃N₄ ceramic, while FeAl-bonded diamond tools demonstrate a higher grinding ratio than NiAl-bonded diamond tools due to enhanced self-sharpening ability. Nevertheless, diamond tools based on both NiAl and FeAl can be used to grind Si₃N₄ ceramics.     

几种小分子酯类有机物对矿渣粉磨性能及矿渣水泥强度的影响

从筛余量、比表面积、粒径分布、胶砂强度、SEM分析等方面研究了几种小分子酯类有机物对矿渣粉磨和矿渣水泥强度的影响。结果表明：几种酯类物质均能降低矿渣筛余量,增加比表面积,提高3μm~32μm颗粒含量,对矿渣具有良好的助磨效果;酯类有机物分子的链长越长（对称结构除外）,官能团越多（官能团相距较远）,助磨效果越好;链长相同时,官能团数目的影响占主导地位。酯类物质的加入能使矿渣水泥水化产物Ca（OH）2成片层状紧密生长,能有效提高矿渣水泥的强度。