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TABLE OF CONTENTS
Title page
Table of Contents
Abstract
CHAPTER ONE
INTRODUCTION
1.0. Introduction
1.1. Background of Research
1.2. Statement of Research Problem
1.3. Justification
1.4. Aims and Objectives
1.4.1. Aim
1.4.2. The specific objectives
1.5. The Scope of the work
CHAPTER TWO
2.0. LITERATURE REVIEW
2.1. Failure Analysis Overview
2.2. Causes of Failure
2.3. Wear Mechanisms as Agent of Failure
2.3.1. Adhesive Wear
2.3.2. Abrasive Wear
2.4. Failure Induced by Ore Hardness Values
2.5. Mill used for Grinding Mineral
2.6. Minimization of Failure through Wear Reduction
2.7. Materials used for Grinding Mineral Ores
2.8. Carbon Equipment Value (C.E.V)
2.9. Effects of Some Alloying Elements in Cast iron
CHAPTER THREE
3.0. MATERIALS, EQUIPMENT AND GENERAL EXPERIMENTAL PROCEDURES
3.1. Materials
3.2. Equipment
3.3.0 Methodology
3.3.1. Determination of the hardness of the as-received and
developed samples
3.3.2. Impact strength determination of the as-received and
developed samples
3.3.3. The development of new high wear resistant grinding
plates
3.3.4. Determination of wear rate of the plates
3.3.5. Microstructural assessment of the samples
3.3.6. Characterization of the gold-bearing mineral
3.3.7. Characterization of the as-received grinding plates
3.3.8. Determination of the work index of the gold bearing
minerals
CHAPTER FOUR
4.0. RESULTS
4.1. Hardness Values
4.2. Impact Values
4.3. Wear Rate Results
4.4. Average Wear Rate of the Investigated Samples and their
Corresponding Hardness Values
4.5. Microstructural results
4.6. Highlighted in tables 4.8-4.11 are the chemical analysis
results of the gold-bearing minerals sample 1 and 2, the as-received grinding
plates sample A and B and the hardness and impact values of the mineral samples
4.7. The Work index of the Minerals
CHAPTER FIVE
5.0. DISCUSSION OF THE EXPERIMENTAL RESULTS
5.1.0. Mechanical Properties of the Investigated Samples
5.1.1. Hardness properties of the as-received and developed
samples
5.1.2. The impact strength of the as- received and developed
samples
5.2.0. Wear Rate Values of the Investigated Samples
5.2.1. As- received
sample A
5.2.2. As- received
sample B
5.2.3. Developed sample C
5.2.4. Developed sample D
5.3. Correlation between the Average Wear Rate and Hardness
Values
5.4. Microstructural Analysis of the Investigated Samples
5.4.1. As- received sample A
5.4.2. As- received sample B
5.4.3. Developed sample C
5.4.4. Developed sample D
5.5. The Chemical Analysis of Gold-bearing Minerals
5.6. The Chemical Analysis of the As- received Grinding
Plates Samples
5.7. The Work index of the Gold-Bearing Minerals
5.8. Cost to Manufacture New Grinding Plates
CHAPTER SIX
6.0. SUMMARY, CONCLUSIONS AND RECOMMENDATIONS
6.1. Summary
6.2. Conclusions
6.3. Recommendations
6.4. Contribution to Knowledge
REFERENCES
APPENDICES
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).
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