In mineral processing industries, grinding process is performed in
tumbling mills that describe a class of mills delimited by a
cylindrical chamber filled with balls and/or rock that rotate
around its longitudinal axis. These tumbling mills range in size
from small 0.3 m diameter lab mills to a 16 m diameter
semi-autogenous industrial mill and are driven by chain and
sprocket (lab mills), gear and pinion (pilot and industrial scale
mills) and gearless drives in very large diameter mill (8 to 12 m
dia.). All of these mill drives present advantages and limitations.
In this work, we focus on the design and development of a ball mill
with cam-driven that results in a very considerable reduction in
friction by the substitution of rolling friction for sliding
friction. An alternative drive system is presented that uses a
newly patented speed-o-cam technology and applies it to a 5 ft
diameter mill. We introduce polynomials to modify the cam profile
around both the cusp and the blunt point of the profile to improve
pressure angle and shock impact. We build models of mechanical
systems, simulate the full-motion behavior of the models, and
analyze multiple design variations. We integrate the theoretical,
virtual and experimental analyses in order to design an optimal
mechanical system. Moreover, the analysis of static and dynamic
forces of cam mechanism is reported in the work.
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