Numerical Simulation Research Of Ball Mill Characteristics With Different Grinding Media And Fill Level

Ball mill is a general equipment used to crush and grind materials.It has a wide range of applications in important industrial fields such as mining,metallurgy,chemical industry,and energy.However,during the operation of the ball mill,the energy consumption of the ball mill is huge,and the energy efficiency is very low.Therefore,how to reduce the energy consumption and increase the energy efficiency of the ball mill has become a research hotspot in the ball milling process.The shape of the grinding media,the loading fill level of the material,and the fill level of the grinding media are important factors affecting the efficiency of the ball mill.This paper uses the Discrete Element Method(DEM)to study the influence of the above factors on the ball mill system.The operating characteristics of the ball mill under the shape of the media,the fill level of material,and the fill level of grinding media.The main research contents are as follows:(1)Using a non-spherical discrete element model based on a super-ellipsoid,the influence of the shape of the grinding media on the operating characteristics of the ball mill was studied.First,the accuracy of the DEM model is verified by comparison with experimental data.Then,based on the super ellipsoid model,three cylindrical particles were established to describe the steel forging grinding media in actual production,and the working process of a ball mill loaded with different shapes of grinding media was simulated.The results show that the spherical grinding media is more suitable for high energy impact crushing of materials,and the cylindrical grinding media is more suitable for low energy and high frequency grinding of materials.(2)Using large-scale discrete unit numerical analysis,the influence of the loading amount of mining-scale industrial-scale ball mills on their operating characteristics was studied.First,the accuracy of the DEM model is verified by comparison with experimental data.Then,under the condition that the fill level of the grinding media is unchanged,five groups of ball mill models with different material filling rates are established,and the simulation is performed under the same rotation speed.The research results show that the low fill level of the material will increase the energy consumption of the ball mill and increase the wear of the liner of the ball mill;the high fill level of the material will reduced the crushing capacity of the ball mill.(3)The discrete element method was used to study the influence of fill level of the grinding media on the operating characteristics of the ball mill,and the correlation between the collision between the grinding media and the liner and the vibration characteristics of the ball mill was established.First,under the condition that the material fill level is unchanged,three sets of ball mill models with different filling media filling rates are established,and the simulation is performed under the same rotation speed.Then,the collision energy acting on the lining is related to the characteristic value of the vibration in the experiment,and the mechanism of noise generation in the production of the ball mill is explored.The research results show that the high the fill level of the grinding medium will increase the consumption of the steel ball and the liner,and the low fill level of grinding media will cause the ball mill to reduce the ability of the material to be crushed.The high energy impact of the grinding media on the liner of the ball mill is the main reason for the severe vibration and sound of the ball mill..The research results in this paper have guiding significance for the design and improvement of the automatic control system for the optimal operation of the ball mill.