Wear prediction of ball mill liners using DEM-based models

This study explores wear prediction in ball mill liners using Discrete Element Method (DEM) simulations and experimental assessments. We compare a newly designed stepped liner made from high-chromium alloy to traditional liners in a laboratory-scale ball mill. The DEM simulations predicted wear patterns based on Archard’s wear law, while experimental trials evaluated wear characteristics under varied milling conditions. Results showed that the new liner significantly reduced wear depth and mass loss—approximately 70% less after 500 hours—attributable to its optimized geometry and material properties. These findings validate the DEM models and highlight the potential for improved milling efficiency and reduced maintenance costs through innovative liner design.