Analysis and Design of a Double-Chamber Centrifugal-Gyratory Mill for Fine and Ultrafine Comminution

Margarita Aldanova, Bakhyt Narikbayevich Absadykov, E. S. Askarov, A. Kawałek, A. S. Ibraim, Assylbek Kassenov, Gulsunoy Abdukarimova, Tursunov Zakir

2026

Full text Open access: Gold Metadata (CSL-JSON)
DOI 10.3390/ma19194036
Data confidence 70 medium
How this score is calculated

It is built from checkable properties of the record itself: whether the article has a DOI, how many independent sources confirmed its data, whether the required fields are filled in, and how recent the latest confirmation is. Disagreement between sources and a missing identifier lower it. A value of 80 or above means the record was published without further checking; 60 to 79 means it is published at reduced confidence, with a manual check advisable. A record verified by an editor by hand is never pushed below 90 by a recalculation. This scores our data about the article, not the article itself.

Abstract

This study presents the analysis, design, and experimental–numerical evaluation of a double-chamber centrifugal-gyratory mill developed for the fine and ultrafine grinding of mineral raw materials. The operating principle is based on plane-parallel circular motion of two cylindrical grinding chambers generated by a crank mechanism. This motion produces an intensified centrifugal field and promotes simultaneous impact, compression, abrasion, and interparticle breakage within the grinding zone. An analytical model was developed to evaluate the influence of crank radius, rotational speed, chamber geometry, and grinding-body mass on the forces governing material destruction. At a crank radius of 15 mm and a rotational speed of 500 min−1, the calculated centrifugal force acting on a 7 kg grinding body reached approximately 288 N, which is 4.2 times greater than its gravitational force. This confirms that the investigated grinding process is controlled predominantly by dynamically generated centrifugal loading rather than by gravity alone. Physical grinding tests demonstrated the ability of the mill to fracture hard mineral samples under intensive operating conditions, confirming the practical effectiveness of the combined impact–compression mechanism. Structural performance was assessed using global and local finite element models developed in Autodesk Fusion. The complete double-chamber assembly, subjected to three applied moments of 900 N·m, exhibited a maximum von Mises stress of 22.915 MPa, a maximum displacement of 0.050 mm, and a minimum safety factor of 9.033. The local shaft–chamber–support model, analysed under a torque of 500 N·m, produced a maximum stress of 65.837 MPa, a displacement of 0.740 mm, and a minimum safety factor of 3.144. In both numerical models, the maximum stresses remained substantially below the assigned steel yield strength of 207 MPa. The combined analytical, experimental, and numerical results demonstrate that the proposed mill generates sufficient dynamic loading for hard-rock breakage while maintaining adequate structural strength, stiffness, and operational safety under high-torque conditions.