FAILURE ANALYSIS AND DEVELOPMENT OF HIGH WEAR RESISTANT LOCALLY- MANUFACTURED GOLD – MILL GRINDING PLATES, A RESEARCH PROJECT TOPIC ON MECHANICAL ENGINEERING
Abstract
The research work is centered on the failure analysis of the as-received locally produced grinding plates, development of high wear resistant grinding plates capable of grinding gold-bearing mineral deposit in Bagega village of Zamfara State. The work was carried out by evaluating the chemical compositions of the as-received grinding plate samples, the compositions of the gold-bearing mineral samples, the microstructures of the as- received and developed grinding plate samples, mechanical properties (impact strength, hardness values) and wear rate of the as-received and developed grinding plates using Optical Emission spectroscopy (OES), Energy Dispersive X-ray Fluoresce (ED-XRF), Metallurgical microscope, impact and hardness testing machine, and the grinding machine. The analysis showed that the as-received locally produced grinding plate samples were grey cast iron with pearlite structure as the major matrix together with few cementite structures, generally characterized by poor mechanical properties. This explained the wear resistance of the samples in supporting grinding of the charged mineral for a longer period thereby prompting the samples to wear and fracture quickly in service. The two locally developed white iron base grinding plate samples showed a remarkable improvement in mechanical properties and wear resistant ability with increase in grinding duration from thirty two to seventy five minutes due to the presence of alloying elements that are capable of promoting abrasive wear resistant in comparism with the as-received failed grinding plates.
CHAPTER ONE
1.0. Introduction
Failure analysis is the process of collecting and analyzing data to determine the cause or causes of failure in general. It is the process by which scientists, technologists, engineers and business analysts use to assess the failure mechanism of any component in service that failed. It is an important area in every manufacturing industry (Neville, 2011).
Due to one reason or the other, machine component often experiences one form of service failure- the consequences which could include death and financial losses. Legal ramifications have encouraged the development of effective failure analysis method. While the cost of failure analysis may exceed the value of the part damaged, in some instances the cost of service failures usually far exceeds the cost of failure analysis (Neville, 2011).
