Comminution in the Minerals Industry

Size reduction processes represent a significant part of the capital as well as the operating cost in ore processing. Advancing the understanding of and improving such processes is worthwhile since any measurable enhancement may lead to benefits, which may materialize as reductions in energy consumption or wear or improved performance in downstream processes. This book contains contributions dealing with various aspects of comminution, including those intended to improve our current level of understanding and quantification of particle breakage and ore characterization techniques that are relevant to size reduction, as well as studies involving modeling and simulation techniques. The affiliations of the authors of the articles published in this book span 14 countries around the globe, which attests to the highly international nature of research in this field. The themes of the manuscripts also vary widely, from several that are more focused on experimental studies to those that deal, in greater detail, with the development and application of modeling and simulation techniques in comminution. Size reduction technologies more directly addressed in the manuscripts include jaw crushing, vertical shaft impact crushing, SAG milling, stirred milling, planetary milling, and vertical roller milling. Ores involved directly in the investigations include those of copper, lead–zinc, gold, and iron as well as coal, talc, and quartz

Review of current best-practices in machinability evaluation and understanding for improving machining performance

Machinability is a generalized framework that attempts to quantify the response of a workpiece material to mechanical cutting, which has been developed as one of the key factors that drive the final selection of cutting parameters, tools, and coolant applications. Over the years, there are many attempts have been made to develop a standard evaluation method of machinability. However, due to the complexity of the influence factors, i.e., from work material and cutting tool to machine tool, that can affect the materials machinability, currently there is no uniquely defined quantification of machinability. As one of the outcomes from the CIRP's Collaborative Working Group on “Integrated Machining Performance for Assessment of Cutting Tools (IMPACT)”, this paper conducts an extensive study to learn interacting machinability parameters to evaluate the overall machining performance. Specifically, attention is focused on recent advances made towards the determination of the machinability through tool wear, cutting force and temperature, chip form and breakability, as well as the surface integrity. Furthermore, the advanced methods that have been developed over the years to enable the improvement of machinability have been reviewed

Nanocomposites for Machining Tools

Machining tools are used in many areas of production. To a considerable extent, the performance characteristics of the tools determine the quality and cost of obtained products. The main materials used for producing machining tools are steel, cemented carbides, ceramics and superhard materials. A promising way to improve the performance characteristics of these materials is to design new nanocomposites based on them. The application of micromechanical modeling during the elaboration of composite materials for machining tools can reduce the financial and time costs for development of new tools, with enhanced performance. This article reviews the main groups of nanocomposites for machining tools and their performance

Electro-Discharge Machining of Ceramics: A Review

Conventional machining techniques of ceramics such as milling, drilling, and turning experience high cutting forces as well as extensive tool wear. Nevertheless, non-contact processes such as laser machining and electro-discharge machining (EDM) remain suitable options for machining ceramics materials, which are considered as extremely brittle and hard-to-machine. Considering the importance of ceramic machining, this paper attempts to provide an insight into the state of the art of the EDM process, types of ceramics materials and their applications, as well as the machining techniques involved. This study also presents a concise literature review of experimental and theoretical research studies conducted on the EDM of ceramics. Finally, a section summarizing the major challenges, proposed solutions, and suggestions for future research directions has been included at the end of the paper

DEFECT PHENOMENA IN SUPERCONDUCTING OXIDES AND ANALOGOUS CERAMIC OXIDES

In this review we discuss defect phenomena in superconducting oxides. We survey those aspects of oxide superconductors which relate them most closely to conventional ceramic oxides, concentrating on processes and behaviour related to defects. We also identify areas of difference between two types of oxide.Theoretical modelling of conventional oxides has been extremely effective, and we emphasize that some of these modelling tools can be exploited for the superconducting oxides too. In particular, we stress those methods and ideas that provide a framework for understanding behaviour, those that provide a datasbase of good quantitative experiments and those that provide an established and tested approach to quantitative modelling as a guide to prediction, optimization and extrapolation.Much progress has been made in both theory and experiment, but some problems do remain and these have not been omitted from our discussions. There is potential to exploit past work on defects in oxides, so as to control defect processes and microstructure and hence to enhance performance

Grinding of riblets with "beaver tooth" multi-layer tools

To reduce friction in turbo machinery components, riblets are induced on compressor blades or pump impellers. Here, the grinding process enables a higher productivity in machining of riblet structures compared to knurling, laser or milling operations. Usually, profiled grinding tools are used to create such structures inspired by sharkskin. Unfortunately, conventional grinding tools have to be dressed continuously to keep the desired profile in the circumferential surface. To avoid the time-consuming dressing process and to enable a self-sharpening effect, an innovative multi-layer tool concept is developed. The tool consists of two types of thin polyimide layers. The first type contains abrasives and the second is a support layer without abrasives. These layers are piled alternately in a special manufacturing process and act like a monolithic tool in grinding process. The aim of the investigations presented in this paper is to find an optimal parameter setting to produce riblet structures productively by using the self-sharpening effect. The optimal setting allows a grinding process without any dressing process by using a large part of the grinding tool volume. At first, the manufacturing process is focused to create clearly divided support and abrasive layers of the grinding tool. Furthermore, the investigation shows the relationship between grinding parameters and the setback of the supporting layer in the middle of the tool. This setback is important for the creation of riblet structures in the surface of AISI 420 workpieces