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A preliminary examination of blades wear in a planetary concrete
mixer
M.Cristina Valigi1, Ilaria Gasperini2.
1
Department of Industrial Engineering (DIIN), University of Perugia, Italy
E-mail:mc.valigi@unipg.it
2
SICOMA, Societ Italiana Costruzione Macchine, Ponte Valleceppi (PG), Italy
E-mail: ilaria.gasperini@sicoma.it
Keywords: Wear, concrete mixer, blades.
1 INTRODUCTION
The wear effect is the progressive modification of surfaces morphology that brings, in a short
time, the mechanical components to the final inefficiency. In the examined concrete mixer the
blades result the components more suffering the wear. The mixing function does not appertain to
the blades, but their function is unload the mixer, pushing the concrete to discharge opening. They
are made so that they can be easily changed when the wear is proceeded and the unload function is
almost inhibited. In order to extend the life of the blades, a new shape is proposed studying the
mixing process and its characterization.
The mixer power evolution with respect to operating time, describes the process as presented
in literature [4].Particles were wetted and a power consumption increased. Thereafter, power
consumption leveled off at a plateau and then further increased during the wet phase. In the final
phase, power consumption drops as the mass becomes a suspension (pseudo-fluid). In the power
absorption diagram, phases could be localized in which particular transformations occur. Many
authors [1],[5],[6],[7]. have proposed models of mixture evolution correlated with the type of
microstructure in various states stages (see Figure 1). In order to improve the performance of the
mixer some authors [3] have proposed an analytical model for force estimation on arms, that is
very useful for mechanical design.
In this paper the main task is to analyze the wear of the blades and propose new shape with
high wear resistance.
Figure 1: Mixture evolution with type of microstructure in various states stages.
Actually the mixer distributes all the constituents uniformly in the tank without favoring one or the
other. The blades (one for each arm) can reach all points of surface tank in a short time as the
Figure 3 shows.
The mixer has to start empty before the loading operation, the loading of water has to occur in a
short time in order to gain the production time.
Therefore a fast loading of water means a short time in which the mixer is subject to the
largest effort (the absorption power reaches the 120% of nominal value). The final mix time
depend on the time of previous phases.
Regarding the concrete mixing operation, we can pick out three principal phases [2]:
Phase 1: first mixing phase, aggregate and cement are inserted in the mixer without water, dry
phase,
Phase 2: a proper quantity of water is added to the dry mix for final mixing, wet phase,
Phase 3: final mixing of concrete before unloading for complete homogenization of the mix. Some
authors have shown how the Brinch-Hansen formula (derived from Terzaghi theoretical model)
[3] and the Bingham theory of fluids [1][2] can be used to describe the behavior of concrete
respectively in the so called dry and final mixing phases. For the second phase there is not a
consistent theoretical model for the materials because the water addition time is usually very short
compare to the time of other phases. Figure 4 shows the power absorption of the motor during a
typical mixing cycle. In the power absorption chart two stages are highlighted during mixing:
- At the beginning of the mixing cycle, the power absorption has strong and rapid variations
that results as a competition between excess liquid zones and unsatured zone.
- After a given mixing time, the mixture has already formed as a fluid-like material and the
evolution of power drops to become smooth.
The moment when the power consumption decrease suddenly is the time of transition from a
cohesive mixture to a uid-like material. After the transition time, the flow is governed by viscous
effects [1].
transition time
Figure 4: Typical power absorption of motor in the time for the analyzed mixer.
Some different causes of electrical power absorption during the mixing can be individuate.
The energy is dissipated in mixture flow mainly by friction for the dry granules states or dry power,
by cohesion when granules are wetted in surfaces and by viscous effect in the granular suspension
state. Cazacliu et al. have modeled [1] the origin of power absorption, with the forces that
counters blade progression with two components: frictional Sf and viscous Sv.
S d L
f 0 (1)
The frictional force is proportional to the contact between the surface of blades and the tank, that
is present in the bottom zone and lateral zone.
Where 0 is the frictional tangential action depending on the type of the concrete in mixing, d is
the distance between the tank and the blade surfaces and L is the characteristic dimension of blade
( that is the length).
The viscous component Sv is function of the concrete apparent viscosity that is, according to the
Bingham formula, the following:
*
0 (2)
And where is the velocity gradient in the blade vicinity:
*
S s L n v (3)
v
where s is a viscous coefficient and n the normal to the blade surface.
The power consumed by a blade is:
(4)
P S S v
v f
According to the models present in literature the concrete is considered a polifasic fluid with a
behavior as a Bingham material. A Bingham material is a viscoplastic material that behaves as a
rigid body at low stress but flows as a viscous fluid at high stress (Figure 5).
The shear yield stress o depends on the friction and cohesion stress of slurry, on attraction of
concrete particles, on friction stress and on ratio water/concrete and it influences the slump. The
plastic viscosity depends on the quantity and on the type of idles.
3 WEAR BLADES
The blades suffering wear more than others parts of mixer because are completely invested by
the material in mixing. The part of blades that results more worn is the extreme one that works in
the circumferential zone of tank, that part has a fundamental role during the unloading phase
because push the concrete against the discharge openings. In Figure 6 there are two blades: a new
one and a blade that is at the end of its life. The wear in the blade is more evident in the right zone
(that is the extremity of the blades). This behavior is typical for all the blades. The material of
mixer blades is cast-iron Ny-Hard with hardness of about 550-600 HB, with a high wear resistance.
The composition of alloy is the following: 3.25%C, 1.59%Si, 1.44Mn, 0.075%S, 2.86%Ni,
1.54%Cr.
4 PROPOSED SOLUTIONS
Because the wear regards prevalently the right extremity, at beginning, the blades were
modified by SICOMA with a thickening of that side in order to increase the wear resistance.
Figure 8 shows the comparison of blades with and without thickening. This modification was a
result of the collaboration between customers and firm. In this way the goal was reached, but in
order to improve further the performance of mixer in this paper a new shape of blade is proposed
on the basis of theoretical models described.
The new blade has a pleat: in the internal part it is like the current blade (with the same angle),
but since the middle of the front line it has a bigger angle.
(a) (b)
Figure 11. Trajectories of the actual (a) and the proposed blade (b) in 5 different points of the
front line.
(a) (b)
Figure 12. Speed of the actual (a) and the proposed blade(b) in 5 different points of the front line .
Figure 12 shows the speed of actual and proposed blade in five different points of the
front line and Figure 13 the speed along the frontline.
The speed is lower in the extreme of the proposed blade compare to the actual blade; for this
reason some prototype blades are made forecasting a better resistance wear because a lower
viscous force.
(a) (b)
Figure 13. Speed of the actual (a) and the proposed blade (b) along the line defining the blade.
References
[1] B. Cazacliu, J. Legrandb., Characterization of the granular-to-fluid state process during
mixing by power evolution in a planetary concrete mixer, Chemical Engineering
Science 63,(2008), 4617-4630.
[2] B. Cazacliu , N. Roquet., "Concrete mixing kinetics by means of power measurement
Cement and Concrete Reserch 39, (2009) 182194.
[3] C.Braccesi,L.Landi "An analytical model for force estimation on arms of concrete
mixers Proceedings of the ASME 2009 International DETEC/CIE,2009, San Diego,
California, USA.
[4] H.P.Bier, H . Leuenbeger, , H. Sucker, Determination of the uncritical quality of
granulating liquid by power measurements on planetary mixers. Pharmazeutische
Industrie 41 (4),(1979) 375380.
[5] B. Cazacliu,"In-mixer measurement to describe the mixture kinetics during concrete
mixing" Proceedings of sixty International on Mixing in Industrial Process Industries,I
SMIP VI , 2008,Niagara on the Lake, Niagara Falls, Ontario,Canada.
[6 ] B. Cazacliu,"In-mixer measurement for describing the mixture evolution during concrete
mixing"Chemical Engineering Research and Design 86,(2008), 1423-1433
[7] A.Goldszal, J. , Bousquet, , Wet agglomeration of powders: from physics toward
process optimization. Powder Technology 117,(2001) 221231.
[8] M.C. Valigi , I.Gapserini, Planetary vertical concrete mixers: Simulation and predicting
useful life in steady states and in perturbed conditions Simulation modeling Practice and
Theory.15 (2007) 1211-1223.