SUMMARY

Numerous tests used in identifying the rock abrasiveness exist which can

help in estimating wear. One of the widely used rock abrasion test is the

CERCHAR Abrasivity Index (CAI). This test is used for estimation of bit life and

wear in various mining, tunneling and drilling applications. The test is simple and

can be considered for field application. This apparatus will help in predicting the

wear of the drilling bit. It will also permit the optimal selection of bit, replacement

rates and scheduling maintenance and the life expectancy for the drill bit.

CERCHAR Abrasivity test was invented in France in the mid-1980s. The

testing principle is based on a steel pin with defined geometry and quality that is

used to scratch on the rock surface at a standard distance of 10 mm resulting to

wear produced on the tip of the pin. The use of this test in various research

institutes has led to CAI being a standard parameter for hard rock classification.

The CERCHAR abrasivity index (CAI) is then calculated as the average

measured worn flat diameters on the testing needle with the following equation:

𝑑
𝐶𝐴𝐼 = 10 ∗
𝑐

CAI = CERCHAR Abrasivity Index

d = diameter of wear flat (mm)

c = unit correction factor (c = 1 mm)

 The obtained CAI results were based on the reference values shown in the

table below:

Abrasivity Classification of Different Rock Types based on CERCHAR Test

CERCHAR Abrasivity Abrasivity Types of Rocks
Index Classification
0.1 – 0.4 Not abrasive Organic Material

0.5 – 0.9 Not Very Abrasive Mudstone, marl

1.0 – 1.9 Slightly Abrasive Slate, Limestone

2.0 – 2.9 (Medium) Abrasive Schist, Sandstone

3.0 – 3.9 Very Abrasive Basalt, Quartzitic

sandstone
4.0 – 4.9 Extremely Abrasive Amphibolite, Quartzite

Source: CERCHAR Abrasivity Index (CAI), Thuro et al. (2007)

The main objective of the study was to design and develop an automated

CERCHAR Abrasivity Index apparatus for measurement of rock abrasion

considering its design specifications for automation using locally available

materials.

The materials used for stylus was the standard alloyed cold-work tool steel

with a Rockwell hardness of HRC 55 and a conical tip angle of 90°. It should have

a diameter of at least 6 mm and a length of at least 15 mm based on ASTM D7625.

The rock samples were cut in cubical shape in order to execute the CERCHAR

test on a flat surface and should be held firmly in the vise clamp for no-slip grip

during the test. The rock specimen has a maximum width of 150 mm (6 in.) and

height of 76 mm (3 in.).
 The rock samples used were sandstone, basalt, limestone, granite,

dolomite, and shale. The sandstone was collected from San Juan, Batangas. The

basalt and granite were from Mabini and the shale, limestone, and dolomite were

gathered from Taysan, Batangas.

The parameters established in the preliminary testing of the apparatus were

the operating load, operating time, operating speed and testing length. Six rock

samples were tested under 50 Newton, 70 Newton and 90 Newton operating load.

The speed used in testing were 300 rpm, 800 rpm and 1300 rpm. Each rock type

was tested under three different load and three scratching speed. The time it took

for the pin to reach the 10 mm standard distance was recorded as the operating

time. Upon evaluating the results, the parameters obtained were as follows; (a) the

operating load of the apparatus was 70 Newton; (b) the operating speed was 1300

RPM.

Final testing was conducted to evaluate the performance of the apparatus.

Diameter of tool wear and CAI values were the parameters included in the final

testing.

The results obtained using the apparatus were compared according to the

reference ranges of values of different kind of rocks according to Thuro et al. (2007)

as specified by CERCHAR test.

The study provided an operational manual and maintenance manual for the

laboratory apparatus for measurement of rock abrasivity.

The process for the development of this study was first, the researchers had

to conceive the required knowledge about rock properties; second was the
development stage where they created a proposed design layout then automate

the new CERCHAR abrasion apparatus for rock abrasion considering proper

selection of materials; hardware requirements such as material specifications and

system components; next was the identification of different parameters that were

essential to the study on the said objectives. After fabrication, it was followed by

implementation of preliminary testing, modification, analysis and evaluation of the

performance of the apparatus.

The output of this research was to automate the CERCHAR Abrasivity Index

(CAI) apparatus for measurement of rock abrasion with an operation manual that

would serve as a guide for proper use of the CAI apparatus. The operating

provcedures were derived based on the standard test method for laboratory

determination of abrasiveness of rock using the CERCHAR method which is the

ASTM D7625. The automated CAI apparatus adopted the mechanisms to produce

reliable results.

The findings acquired from the design and development of a laboratory

apparatus for rock abrasivity measurement were summarized as follows:

1. Locally available materials were used on the development and fabrication

of the prototype. Each system components were analyzed to meet the material

specification needed in the prototype. System components, material specifications

and safety mechanism were considered in fabricating the prototype.

 2. The rock samples used were Basalt, Sandstone, Andesite, Limestone,

Dolomite, and Shale. Basalt is the hardest while the Shale is the softest. The rock

samples were cut into cubical shape to allow scratching on flat surface and to be

held firmly in the vise clamp.

3. The parameters established in the preliminary testing of the apparatus

were the operating load, operating time, operating speed and testing length. Six

rock samples were tested under 50 Newton, 70 Newton and 90 Newton operating

load. The speed used in testing were 300 rpm, 800 rpm and 1300 rpm. Each rock

type was tested under three different load and three scratching speed. The time it

took for the pin to reach the 10 mm standard distance was recorded as the

operating time. Upon evaluating the results, the parameters obtained were as

follows; (a) the operating load of the apparatus was 70 Newton; (b) the operating

speed was 1300 rpm.

4. The parameters established from the preliminary testing were used to

conduct the final testing to determine the diameter of tool wear and CERCHAR

Abrasivity Index (CAI) using a camera module. Six different rock types were

examined under three trials. The following results were obtained: For Basalt, the

average wear diameter produced by the pin was 0.3707 mm and CAI value of 3.7;

for Sandstone, the average wear diameter was 0.2520 mm within 6.65 s and an

average CAI value of 2.5 mm; for Andesite, the average wear diameter was 0.2517

mm, scratch time of 6.52 s and CAI value of 2.5; for Limestone, the average wear

diameter, scratch time, and CAI value was 0.1722 mm, 6.42 s, and 1.7,

respectively; for Dolomite, the average wear diameter was 0.1470 mm, average
scratch time of 6.30 s, and an average CAI value of 1.5; for Shale, the average

wear diameter was 0.0771 mm, average time of 6.10 s, and an average CAI value

of 0.77.

5. The performance of the apparatus was evaluated by comparing the

CERCHAR Abrasivity Index (CAI) values obtained by the prototype to that of

reference values on Table 7.

6. The higher the applied load, the higher the produced CAI will be.

Selection of the static load to be used in final testing was based on the consistency

of results at varying speed that satisfies the reference values. Effect of testing

length variation on CAI was also examined on six rock samples with dissimilar

hardness. It was observed that the significant amount of pin wear occurs at the

first 5 mm of the testing path. Only a slight quantity of wear was produced after the

standard distance of 10 mm. For Basalt, 63% of the pin wear occurred in the first

5 mm, both 69% for Granite and Sandstone, both 65% for Limestone and Dolomite,

and 62% for Shale.

7. Operation manual has been developed and provided for the future

researchers to have knowledge on how the CERCHAR Abrasivity Index apparatus

works. The manual includes the step by step procedure starting from the

preparation of the sample up to the testing proper. Safety mechanism was also

included on the manual.

 Testing was conducted to determine the results that led to the following

conclusions:

1. The CERCHAR Abrasivity Index Apparatus was fabricated using most

economical and available materials. Through the tests conducted, the

prototype was proven to be efficient and safe to use.

2. By cutting the rock samples into cubical shape and maximum width of

150 mm (6 in.) and 76 mm height (3 in), the testing was successful and

the pin with hardness HRC 55 was more stable during scratching. The

rock sample was held firmly in place and can be easily fitted into the vise

clamp.

3. Based on the preliminary testing, the abrasivity of rocks was greatly

affected by the operating parameters used in the study such as the

operating load and operating speed. Wear diameter and CAI values vary

from the applied load and scratching speed. The scratching time

depends on the operating load and the operating speed and also

depends on the type of rock samples used. As the operating load

increases, the scratching time decreases and as the operating speed

increases the scratching time also increases. The harder the rock

sample the longer it takes for the pin to reach the standard scratching

distance of 10mm.

4. The diameter of tool wear and CAI values of rocks depend on the

hardness of the rock sample examined. With the application of the

established parameter, 70 N and 1300 rpm, the produced wear diameter

 and CAI values were able to satisfy the reference values of all six rock

samples.

5. When compared to the reference values, the CAI values were able to

satisfy the ranges of all six rock samples. Therefore, applied load of 70

N and 1300 rpm scratching speed were applicable to all the six rock

samples.

6. The applied load and scratching speed greatly affect the CAI produced.

As the applied load increases, the abrasivity index of a rock also

increases. The significant amount of pin wear was produced at the first

5 millimeters of the testing length. The test on the effect of testing length

on CAI values was highly influenced by the rock strength.