Post-Submission Defense of Dissertation-MME 482

Subho Basu
PART OF CURRICULAM OF
4th SEMESTER ,MASTER OF TECHNOLOGY IN
MECHANICAL ENGINEERING

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 DISSERTATION TOPIC

Wear Package Modeling of Buckets for Large

Hydraulic Excavator with Backhoe attachment
for development of correlation between
bucket variables and Wear Package Variables.

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 Literature Review
Archard, J.F. (1953) has developed first relation of volume of wear .The equation can
also be reworked to measure wear depth or wear rate.

Khruschov, M.M., 1957 has shown the relationship of rate of wear between abraded
material and abrasive material are dependent on their hardness ratio.

Rabinowicz, E., 1980 shown in the abrasive wear of metal wear coefficient varies
between a range, depending on the contact conditions and material parameters.

Dudziński, W. Konat, Ł. Pękalski, G. 2008, tested martensitic steel for wear

application with different hardness rating and shown increase in hardness of wear
material can cause severe wear transform to mild wear.

Anderson, S. 2010 investigated wear simulations from a mathematical–numerical

point of view. The wear rate may then be formulated according to his model .

Sarkar, M. Ghosh, S. K. Mukherjee, P. S. 2013, has worked on experimental

determination of dimensionless Archard Constant by experiment for an excavator
bucket and obtained variation of Archard constant over the vertical depth of bucket.

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 Objective
The objective is to develop a general wear protection model for
large backhoe bucket of Hydraulic Excavator. The wear plate
material selection should be linked to the hardness of abrasive
material excavated in such a manner so that specific application
can be taken care of and a desired service life is obtained

As it is a general model development for wear package

installation, it should be correlated to bucket parameters so
that the model can yield desired result on variation of bucket
size and a reasonable service life is obtained. As cost is an
important concern, the same model is used for project
estimation and implementation.

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 Wear Identification

Abrasion is arbitrarily subdivided into broad classifications corresponding to the

nature of the wear material/abrasive particle interaction. The abrasive wear
classifications usually cited include:

• Gouging abrasion (the removal of large volumes of material per event from the
wear surface)
• High-stress grinding abrasion (i.e., the abrasive particle is crushed during the
wear interaction)
• Low-stress scratching abrasion (i.e., the abrasive particle remains intact as it
moves freely across wear surface)
• Erosion (low-stress scratching)
• Erosion-corrosion (low-stress scratching abrasion in a corrosive environment)

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 Constraints
1. Excavator is a lifting machine. Addition of wear
package causes reduction in utilizable payload.
2. Bucket should not be subject to frequent armoring.
The wear package should survive reasonable
service hours.
3. Bucket is built from special steel. Welding of wear
package may cause change in it’s properties.
4. Wear Package should not cause loss of contained
volume within the bucket.
5. Wear package should not retain material in bucket
while dumping material and should not offer
excess resistance while digging.
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 Removal of Constraints
1. The maximum allowable wear package weight to
be determined as per ISO norm.
2. The wear rate for specific application to be
determined.
3. Ratio of Hardness of abraded material vs abrasive
material to be kept above critical level.
4. Welding methods and pre and post heat treatment
to be clearly stated.
5. Wear package should follow bucket contour.
6. Smooth surface for contact with abrasive material
and shape as per bucket shape.

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 Removal of 1st Constraint
1. The maximum allowable wear package weight to
be determined as per ISO norm.
i)Verification of Bucket Volume as per ISO 7451
ii) Maximum allowable suspended load as per ISO
10567
iii) Bulk material density
v) Bucket shell weight: Either by weighing or
geometric estimation with density of plate

All above put together should give an equation for

upper limit of wear package installation. Lower limit is
obviously no wear package.
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 Step 2:Determination of Maximum
suspended weight as per ISO 10567

Maximum Allowable Suspended Load > Bucket Weight + Material density x Bucket
volume+ Maximum Wear Package Weight + safety allowances

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 Step 3: Maximum Digging Force and
Breakout force as per ISO 6015

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 Step 4: Maximum Wear Package Weight
1. Material Load –: Max. allowable density X Derived volume
2. Allowable lift capacity : Bucket+ material wt.+ wear package
wt should be within 75% of Maximum Allowable Suspended
Weight (MASW) or 87% of Hydraulic Lift Capacity
3. Bucket Weight –: Bucket Specific Weight X Volume
4. Digging Force (maximum) – Co-efficient of Friction Between
Ground and Track X Machine Weight – generally – 0.6 X
Machine weight
5. Maximum Wear Package Weight (MWPW)= 75% of MASW-
Bucket shell Weight –Material density X Bucket Volume
6. Allowances for variation taken in bucket load side

MWPW is to be < or = MASW- WShell- 1.05 (Vbucket . dmat)

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 Bucket Burst View

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 Removal of 2nd Constraint
1. The wear rate for specific application to be determined. Ratio of
Hardness of abraded material vs abrasive material to be kept above
critical level.

i-The best-known wear model is

(V/s)= K (FN/H)
where V is the wear volume, s is the sliding
distance, K is the dimensionless wear coefficient,
H is the hardness of the softer contact surface,
and FN is the normal load. This model is often
referred to as Archard’s Wear Law .

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 Removal of 2nd Constraint …contd.
The wear rate for specific application to be determined. Ratio of Hardness of
abraded material vs abrasive material to be kept above critical level.

iii) assuming K, FN, H all are constant for this particular situation with FN
being the digging force, we obtain
dV/dt = K (FN/H). dA/dt…
Now dV/dt = Wear rate , dA/dt= Bucket Surface Velocity
Total bucket travel per hour = nRβ, n= No. of cycles per hour
R= Avg. Radius of bucket rotation. ‘β’ is the angular travel of bucket per
cycle.
dA/dt = nRβ
Rate of volume loss=│dV/dt│max = nRβ K (FN/H)
MWPW /ρ│dV/dt│max=MWPW/ { ρnRβ K (FN/H)}= gi= Service
Hour of wear package

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 Removal of 3rd Constraint
Ratio of Hardness of abraded material vs abrasive material to be kept above
critical level.
-With the increase in hardness ratio r above the critical value rc1, wear
volume of abraded material decreases, and finally almost no wear is seen
when r is close to a critical value rc2 (1 to 1.4;).

So determination of Hardness of material to be excavated also helps to

determine minimum hardness of abraded material or wear package.

Bucket with width ‘W’ is penetrating into ground @ n times/hr in a year of

machine running of “m” hrs/year for “k” years to lose “ t1” thickness plate
with hardness H1 over sliding distance A
Hence total sliding distance traversed = Anmk
Volume lost = t1WA=V
Dimensionless constant : = (t1WA/Anmk) x (H/N)= (t1W/nmk) x (H1/N)

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 Removal of 3rd Constraint…contd..
Ratio of Hardness of abraded material vs abrasive material to be kept above
critical level.
-So, higher the hardness of material”H1” higher is the “K1”constant . Archard
law states, volume loss in wear is inversely proportional to hardness. We
take a second wear plate with a hardness H1 with thickness t2 and same
width over the same bucket and same machine and wears out fully in “m”
hrs in “k” years with penetration in ground as n times per hour. The constant
is K2 for 2nd material.
So, K2= (t2W/nmk)(H2/N)

We get K2/(t2H2)= K1/(t1H1)= Ksu , which helps us in determining Ki

dimensionless constant for a material to be used with Hardness Hi and
thickness ti lost over “nmk” bucket digging cycle.
Now “Ksu” can be determined for a material by simulating the digging action
in intended material. For example, a manipulator with bucket is digging and
unloading in wet sand. Ki values are available for different interfaces and
nominally vary between materials of same or closer composition.
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 Removal of 3rd Constraint…contd..
Ratio of Hardness of abraded material vs abrasive material to be kept above
critical level.

-If Ki nominal variation is ignored for a particular steel –earth abrasive wear
process
We find that t1H1 =t2H2
for equal slide length traversed under equal force. Hence with the increase
in Hardness in choosing material the wear rate is reduced proportionately to
the change of material Hardness.
Reduction in wear package weight = ρ ( t1-t2) X length X Width

2nd Observation : Equal weight wear package with different hardness

If t1= t2 for the above case is taken , we will find service life ‘gi’ will be
proportional to respective hardness Hi
g2/ g1 = H2/ H1
-

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 Removal of 4th, 5th and 6th Constraints
4. Welding methods and pre and post heat treatment to be clearly stated.
-The special steel manufacturer specify the welding methods, pre and post
welding heat treatment

5. Wear package should follow bucket contour.

- Wear Zones to be identified and wear plate laying should follow bucket
surface geometry while laying the pattern

6. Smooth surface for contact with abrasive material and shape as per
bucket shape.
- Plates laid continuously and in a uniform sequence to keep smooth surface
at contact . All over wear zone.

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 Wear Zone of Bucket

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 Bucket Parameters

Maximum Wear Package Weight (MWPW)= ti.ρ.{(π- Ө-φ).r +BD}. (WBUCKET +

WINBUCKET)+ 4 {∆AFD-∆ABO+ (π/2 - Ө) r2 /2} if solid plate covering is done

MWPW is to be < or = MASW- WShell- 1.05 . (Vbucket . dmat)

MWPW/ { ρnRβ K (FN/H)}= g= Service Hour of wear package

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 Reduction in Slide length by
discontinuous surface
If the laying pattern is made discontinuous or providing gaps in between

1. Continuity of sliding length is reduced

2. The Gap created is such that flowing material cannot create wear of parent
surface
3. For Plastic deformation under motion, discontinuity does not let the process
mature over slide length
4. Gaps are not resisting material , so flow of material cannot be subject to
Normal force over gap and cause wear
5. This reduces weight also. The Gap is maintained as 1/3rd or 1/4th of discreet
plate width so that sliding material cannot cause wear to the parent plate.

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 Determination of Wear Package from
Bucket Parameter
1. Weight reduction by using discontinuous wear bars.
2. Net Wear Package Weight is the weight of Wear Bars planned to
cover the wear model (NWPW)

NWPW= ti.ρ.{(2π- Ө-φ).r +BD}. (WBUCKET + WINBUCKET)+ 4 {∆AFD-∆ABO+

(π/2 - Ө) r2 /2}- ρti WINBUCKET{(π- Ө-φ).r +BD}/(j+1)ti + ρti WBUCKET{(π- Ө-
φ).r +BD}/(j+1)ti +{2 x AF x FD - 4ρti {∆AFD-∆ABO+(π/2 - Ө) r2 /2}-
4.w.ti}

3. Weight of Weld Deposit :

ELw= 0.5 (αti)2 Lw ρalloy (XROD/ XWELDDEPOSIT)

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 Determined Wear Package from
Bucket Parameter…contd
Installed wear package weight (IWP) with following

IWP= ti.ρ.{(2π- Ө-φ).r +BD}. (WBUCKET + WINBUCKET)+ 4 {∆AFD-∆ABO+ (π/2 - Ө) r2 /2}- ρti
WINBUCKET{(π- Ө-φ).r +BD}/(j+1)ti + ρti WBUCKET{(π- Ө-φ).r +BD}/(j+1)ti +{2 x AF x FD -
4ρti {∆AFD-∆ABO+(π/2 - Ө) r2 /2}-4.w.ti}+0.5 (αti)2 Lw ρalloy

Wear Plate requirement with thickness ‘ti’

Bottom Curved Section= [{(π- Ө-φ).r +BD}/(j+1)ti].j of width WBUCKET
Inner Curved Section= [{(π- Ө-φ).r +BD}/(j+1)ti].j of width
Side Plates = 2 x AF x FD

Welding Consumable requirement estimating equation

ELw =0.5 (αti)2 Lw ρalloy (XROD/ XWELDDEPOSIT)

ELNO= 0.5 (αti)2 Lw ρalloy/ XWELDDEPOSIT

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 Work Processes for Project
DETAIL SCOPE OF PROJECT QTY/UNIT New Repair
Removal of old adaptors …Nos. Not Applicable Applicable

Fitment of new adaptors by welding …..Nos. Not Applicable Applicable

Cutting of Wear Plates into Wear Bars as per drawing ….Nos. Applicable Applicable
Removal of old wear plate i.e. 50% outside area
……sq.m. Not Applicable Applicable
of both side wall L.H.& R.H.
Installation of new wear plate i.e. 100% outside area
…….sq.m. Applicable Applicable
of both side wall L.H. & R.H.
Removal of 100% old wear plate from both side
…….sq.m. Not Applicable Applicable
inner wall L.H. & R.H. .
Installation of 100% new wear plate in both
…….sq.m. Applicable Applicable
side inner wall L.H. & R.H.
Removal of old wear plate from 75% area of
…….sq.m. Not Applicable Applicable
curved plate inner Area
Installation of new wear plate in 75% area of
…….sq.m. Applicable Applicable
Curved plate inner area
Removal of bottom wear plate, Curved plate outer …….sq.m. Not Applicable Applicable

Installation of bottom wear plate, Curved plate outer …….sq.m. Applicable Applicable

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 Bucket Wear Package Layout-Rear

Bucket Wear Package Layout- Outer Curved Section

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 Bucket Wear Package Layout-Side

Bucket Wear Package Layout- Side Plate

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 Wear Plated Backhoe Bucket

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 Project Cost Model
ACTUAL QTY EXTN
ESTIMATE QTY/
Activity DETAIL /SCOPE OF WORK ITEM (Mtrl/Othrs) /Days RATE in Rs. in
Days(Mandays)
(Manday) Rupees
Phase 1- Design-Drawing-BOM
1 Bucket Measurement O-Designer 1 Day 2 Day Rs./day
Wear Package Design and
2 O-Designer 2 Days 3 Days Rs./day
Drawing
Phase 2- Removal of Old Plates and Gouging
mm length gauging by each
3 M-Gauging Electrode/mm pcs(pkt) pcs (..pkt) Rs./-per pkt
electrode
4 Grinding of gauged area M-Grinding Wheel Nos. Nos. Rs. each
5 Gauging & grinding O-Welder 4 days 5 days Rs./day
6 Gauging & grinding O-Helper 4 Days 5 Days Rs. /day
Phase 3: Wear Plate Cutting and installation
Wear Plate Procurement
7 M- Area X Thickness ……Kg ….Kg Rs/Kg
including offcut allowance
8 Wear plate cutting O-Machinist/Welder 3 Days 4 Days Rs./day
9 Wear plate cutting O-Helper 3 Days 4 Days Rs. /day
Wear plate fitment (mm)
10 M-Electrode ... Kg ….pcs(...pkt) …. pkt Rs…../pkt
Welding length …..mm
11 Wear plate fitment O- Welder 105 pcs /7hrs/day 25 days 27 days Rs./day
12 Wear plate fitment O-Helper 25 days 27 days Rs. /day
Total Wear Package Installation Cost

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 Future Scope of Work
1. 2. The following activities may be taken as scope of future work of this
thesis:
1) This model can be implemented and further refined.
2) A Software Program can be developed to design wear package based on
known inputs.
3) Shape of wear bars can be replaced with square and round replaceable
inserts and further weight and cost reduction can be seen.
4) Effect of work hardening on wear package can be studied.
5) Model can be prepared for Hydraulic and Rope Shovels.
6) Fastening of wear plates in lieu of welding of wear plate or inserts can be
studied.

Even in wear zones , the wear is not uniform. Finite element Method can be
applied to optimize variation of wear plate and pattern across proposed
layout.

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 The END

Thank you.

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