A Review On: “Integrated Experimental and Tribological Investigation of Wear and Failure Mechanisms of Shell Surface of roller in Sugarcane Rolling mill under Variable Operating Conditions

Abstract

Wear and failure of shell surfaces, journals, bearings, and shafts in sugarcane rolling mills remain major causes of reduced operational efficiency, frequent maintenance, and increased production costs due to severe abrasive, adhesive, erosive, and corrosive wear under variable operating conditions. Existing research has primarily focused on isolated tribological investigations, material characterization, finite element analysis, or surface engineering techniques; however, comprehensive studies integrating experimental investigation, tribological evaluation, metallurgical characterization, and numerical simulation for sugar mill roller shell components are limited. Comparative analysis of previous studies indicates that although advanced wear-resistant coatings, heat treatment processes, and finite element-based stress analyses have improved component durability, insufficient attention has been given to the combined influence of sugarcane juice, bagasse fibers, silt particles, and fluctuating crushing loads on shell surface degradation. Therefore, the proposed study presents an integrated methodology comprising a detailed literature survey, industrial field investigations in sugar mill rolling sections, failure data collection, mechanical and metallurgical characterization of roller components, finite element-based static structural analysis under different loading conditions, and the design and development of a customized tribological test rig to experimentally evaluate shell surface wear under simulated operating environments. Furthermore, various operating parameters and advanced surface modification techniques will be investigated to enhance wear resistance and extend service life.
The expected outcomes include identification of dominant wear mechanisms, validation of analytical and numerical stress distributions, development of reliable wear prediction data, optimization of operating parameters, and recommendation of suitable surface engineering solutions for improving the durability and reliability of sugar mill roller shell components. The findings are expected to contribute significantly toward minimizing maintenance downtime, reducing replacement costs, enhancing operational efficiency, and providing practical guidelines for the design and maintenance of tribological components in the sugar industry.