Polymeric Idler Roll Abrasion Resistance Evaluation.

Conveyor belts are extensively used for the transportation of bulk materials due to their safe operation, economy, reliability, and high capacity. The system usually consists of a long-reinforced rubber belt supported by metallic idler rolls; however, certain applications and improper maintenance see these idlers wear. Severe wear that penetrates the idler shell forms sharp edges that might cut the conveyor belt, leading to high costs and operational downtime. Consequently, polymeric idler rolls have been presented as an alternative to improve the performance of conveyor belts, averting the sharp edges of worn idler rolls and, due to their low weight, facilitating idler replacement. However, it is still necessary to assess their technical viability. One essential parameter to be considered is the abrasion resistance of the roll. Several standard test methods, such as the DIN 4649, are used to assess the abrasion resistance of a material. These tests are classified as a twobody abrasion test, in which a (or multiple) hard particle slides over a softer surface. In practice, however, this diverges from field observations, in which three-body abrasion occurs predominantly, i.e., the particles successively indent the surface instead of scratching it. This paper presents a modification to the ASTM G65 test rig to allow three-body abrasion testing to be completed. It then compares the abrasion resistance of six commercial polymeric idler roll segments with a standard steel idler roll under operating conditions that mimic field operation. Finally, the wear mechanisms assessed by SEM are compared with material properties. Overall, the results show that the modified test rig is suitable for ranking idler roll abrasion resistance. [ABSTRACT FROM AUTHOR]