ARTICLE IN PRESS

Biosystems Engineering (2004) 89 (1), 101108

doi:10.1016/j.biosystemseng.2004.05.012
PH}Postharvest Technology

Available online at www.sciencedirect.com

Wear of Rice in an Abrasive Milling Operation,

Part II: Prediction of Bulk Temperature Rise
Debabandya Mohapatra; Satish Bal
Agricultural and Food Engineering Department, Indian Institute of Technology, Kharagpur - 721302, India;
e-mail of corresponding author: sbal@agfe.iitkgp.ernet.in
(Received 11 June 2003; accepted in revised form 27 May 2004; published online 11 August 2004)

The phenomenon of abrasion of rice grains during milling operations was analysed in Part I. This part
includes modelling of the temperature rise and energy utilisation in an abrasion milling operation and its effect
on milling quality of grain. Medium grain brown rice was milled in an abrasive polisher. The rise in the bulk
temperature was modelled by energy balance, on the basis of abrasion wear theory. The head rice yield was
correlated with the nal temperature of the grain and was found to decrease steadily with increase in the bulk
temperature of the grain. The developed model accurately predicted well the bulk temperature rise in the rice
grains with milling time. Energy utilised for milling was found to be about 33%, whereas, about 10% of the
energy was utilised to raise the temperature of the grains, and 5560% of the total energy was utilised in
running the machine in idle conditions.
# 2004 Silsoe Research Institute. All rights reserved
Published by Elsevier Ltd

1. Introduction
Principles of wear nd appropriate application in rice
processing. The mechanism of abrasive wear was
discussed in Part I of this paper and it was found that
wear rate was not only affected by the hardness, length
of cut and load on the material but also by the shape of
the material (Mohapatra & Bal, 2004). In this paper, the
investigations focus is on the effect of abrasion and
friction on the temperature rise in the grain, and its
cascading effect on the milling quality.
The temperature rise due to dissipation of energy loss
at the peaks of the contacting asperities may be of a high
order of magnitude but is of short duration due to the
small area of contact. This temperature, normally called
the ash temperature, has a profound effect on the
friction and wear characteristics of the contacting
surface for the changes in mechanical and thermal
properties (Guha & Roy Chowdhuri, 1996). The energy
supplied during polishing is utilised in polishing, heating
of the grain and overcoming the inertial forces of the
machine, i.e. it is used for idle running of the machine.
Part of the energy for polishing is used in overcoming
the forces of adhesion and cohesion between different
1537-5110/$30.00

layers, resulting in breaking of bonds between the cells.

The cells constituting rice grain include starch, protein
and fat, which are polymeric in nature. These polymeric
bonds easily break due to dissipation of thermal energy.
Once one bond in the polymer has dissociated,
degradation of that polymer chain follows. Thermal
energy distributes itself rapidly along the polymer chain,
so that all of the backbone bonds are exposed to the
energy at some point (Ernest & Porankiewicz, 1999).
In tropical countries, such as India, where high
humidity and temperature conditions prevail in most
rice-growing regions, milling operations yield a very
high percentage of broken grains. During milling, while
bran is being removed, the temperature of the grain
increases simultaneously, thereby causing thermal stress
inside the grain. With the prevailing average ambient
temperature of about 30 8C, the grain temperature after
milling increases beyond 45 8C. The situation deteriorates even more in the summer season, when the
maximum ambient temperature in this region varies
between 40 and 50 8C. This signicantly contributes
to the reduction in head rice recovery, posing a
detrimental effect on rice quality. It is a well-known
phenomenon that changes in temperature cause change
101

# 2004 Silsoe Research Institute. All rights reserved

Published by Elsevier Ltd

ARTICLE IN PRESS
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D. MOHAPATRA; S. BAL

Notation
Ap
b
B
COD
Cpg
E
E0
Ea
Ec
Ef
Eh
Em
Ep
Fc
F0c
Fs
k
L
l
L0
mg
M
Mc

projected area of a single rice grain, m2

thickness of grain, m
width of polisher disc, m
coefcient of determination
specic heat of brown rice, kJ kg
1 8C
total energy input to the system, J
energy under no load condition, J
total abrasion energy, J
abrasion energy on the periphery of the
abrasive wheel, J
frictional energy, J
thermal energy generated to raise the temperature of the grain, J
energy due to change in momentum, J
abrasion energy on the abrasive plate
surface, J
tangential component of the centrifugal
force, N
abrasive force associated with the rotating
grain, N
frictional force, N
coefcient of abrasion
angular momentum, Nm s
length of rice grain, m
change in angular momentum, Nm s
mass of single grain, kg
moment, Nm
torque, Nm

in material properties, increasing susceptibility to cracking/ssuring.

Therefore, the specic objectives of this investigation
are to: (i) develop a model simulating rice-polishing
operation, (ii) predict the rise in bulk temperature using
the developed model, and (iii) quantify energy utilisation
in different stages of a polishing operation.

2. Theoretical considerations
2.1. Modelling of temperature rise in abrasion polishing
of rice grains
Temperature rise of grain was modelled by energy
auditing of the rice-milling operation. In a rice-milling
operation, the increase in temperature of the grain as
well as that of the machine occurs due to partial
conversion of total input energy to thermal energy. The
total electrical energy input to the motor results in
rotation of the polishing wheel relative to grains,
abrasion, mass loss and increase in the temperature of

Mg
n
n0
Nc
Nf
P
Pw
r
R
R0
r0
s
t
Tf
Tfobs
Tfpre
Ti
v
w
YHR
y
o
m
rg

bulk mass of grain, i.e. total mass of grain

under abrasion, kg
number of grains present in the bulk mass
number of data points
centrifugal thrust, N
normal force due to friction, N
relative deviation modulus, %
power, W
radial distance at which grain is abraded, m
radius of abrasive wheel, m
radial distance of the grains present on the
outside periphery, m
radius of the steel core of the disc, m
gap between abrasive disc and screen, m
milling time, s
nal bulk temperature of the grain, 8C
observed bulk surface temperature of
grain, 8C
predicted bulk surface temperature of
grain, 8C
initial bulk temperature of the grain, 8C
peripheral speed of grain/abrasive disc, m s
1
width of rice grain, m
head rice yield, %
angle, 8
angular velocity of disc/grain, rad s
1
coefcient of friction
bulk density of grain, kg m
3

the grain. In the present investigation, the milling system

consists of an abrasive disc of radius R and width B,
rotating inside a casing. The gap between the casing/
screen and abrasive disc is s (Figs 1 and 3).
For development of the model, the following assumptions were made.
(i) The system is in steady-state condition.
(ii) The heat is uniformly conducted away within the
bulk of solids.
(iii) Grain velocity in contact with the rotating disc is
equal to the peripheral velocity of the disc.
(iv) Velocity of grain is zero at the screen.
(v) There is linear distribution of velocity from disc to
screen.
(vi) Clearance between screen and emery element is very
small compared to the radius of the rotating emery
element.
In the abrasive milling system, the abrasive disc
rotates inside a milling chamber. The disc has emery/
abrasive surfaces on both sides of radius R, peripheral
region of radius R and width B. The grains in the

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WEAR OF RICE IN AN ABRASIVE MILLING OPERATION

The frictional force Fs associated with it is

dFs mdNf mrg b o2 r2 dy dr
dNf

Polisher screen
d

Spindle

Steel core

ro

Abrasive wheel
R

Fig. 1. Drawing showing emery disc in a milling chamber: R,

radius of the abrasive wheel; r0, radius of the steel core; r, radial
distance at which the grain is abraded; dy, small angle; dNf,
normal frictional force acting on the emery wheel by the grain
self-weight

immediate neighbourhood, i.e. touching the rotating

emery disc are carried by it and then forced outwards
by centrifugal acceleration. Thus, the velocity of the
grain has both, radial and axial components, and
the mass of grain driven outwards by the centrifugal
force is replaced by an axial motion of the grain within
the chamber. The direction of the frictional forces
is assumed to be uniformly distributed over the
surface.
Analysis of frictional forces on the rotating emery disc
in a grain mass was done in two steps. In the rst step,
the energy required to overcome the frictional forces on
the two sides of the disc was calculated. In the second
step, the energy for overcoming the frictional forces
along the periphery of the disc was calculated analogous
to the principles of the centrifugal pump.

where m is the coefcient of friction.

The direction of dFs must oppose the relative motion
between the emery disc and the grains. The relative
rotation of concentric circles of grain about the centreline generates a couple of forces (dFs1 & dFs2), which are
equal in magnitude and opposite in direction (Fig. 2).
Since the entire milling zone can be subdivided into
small sections, the couple acting on the shaft of the
emery disc can be calculated by integration of the
moments of couples within the boundary of the polisher.
Considering an area element on the ring at radius r, its
moment M in Nm will be given by
dM mrg b o2 r2 dy drr

Solving Eqn (3) for both sides of the emery disc gives

4

R
r40
2


2M 4pmrg o b
4
4
4
where: R is the radius of the abrasive wheel in m; and r0
is the radius of the steel core of the disc in m.
The energy Ef, in J, required to overcome friction for
a time period t in s is given by
Ef pmrg bo3 R4
r40 t

Since at high speed, friction is overcome by abrasion

(Mulhearn & Samuels, 1962; Robinowicz, 1965; Xie &
Williams, 1996), the nal expression in Eqn (5) can be
presented as the abrasion energy Ep in J:
Ep pkrg bo3 R4
r40 t

where k is the abrasion coefcient, replacing the

coefcient of friction.
Abrasive surface

2.2. Energy requirement for the two sides of the

rotating emery disc
Considering an innitesimal area of rdy dr (Fig. 1),
making an angle of dy at the centre, with the vertical
centreline, the grain mass in a single layer just adjacent
to the emery disc will be rgbr dy dr, which moves with an
angular velocity of o at a radial distance of r from the
centre, so the force dNf in N acting on this small element
is (Shames, 1996)
dNf rg br dy dr o2 r

where: rg is the bulk density of grain in kg m
3; b is the

thickness of grain in m; o is the angular velocity of the
emery wheel/grain in rad s
1.

dFS2

Rice grain
r

Vr

Polisher screen

V
dFS1

Abrasive wheel

Fig. 2. Drawing showing frictional forces forming a couple

(dFS1 and dFS2) generated in an abrasive disc rotating in a
milling chamber filled with rice, acting at a radial distance r

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D. MOHAPATRA; S. BAL

2.3. Energy requirement for the peripheral region

of the rotating emery disc
For a cylinder of radius R, consider the periphery of
the emery disc of width B (Fig. 3), where maximum
abrasion on the grain occurs. Since the emery disc is
conned in a milling chamber, where the gap between
the disc and the casing s is very small compared to the
radius R of the emery disc, the grains will experience a
centrifugal thrust Nc in N by the rotating disc of surface
area 2pRB (Shames, 1996).
Since the disc is rotating at a peripheral speed of oR,
the grain mass experiences the following tangential
component of centrifugal force Fc in N
Fc mNc 2pmrg bBR2 o2

Like the previous section, the coefcient of friction can

be replaced by coefcient of abrasion k.
Hence, the abrasion force F 0 c in N is
Fc0 2pkrg B bR2 o2

The torque Mc in Nm exerted by the grain along the

periphery of the emery disc at a distance Rdy is
Z 2p
dMc
2pkBbrg o2 R3 dy
9

Hence, total abrasion energy Ea in J required to abrade

the grain on the side and periphery of the abrasion
element/emery surface is given by Eqn (12), by adding
Eqns (6) and (11)
Ea Ec Ep

12

2.4. Momentum energy

Part of the milling energy is transferred due to change
in momentum of the grain. When the bulk of grain
rotates inside the milling chamber, the ow behaviour
can be represented as the uid ow inside a bound
system. Since the gap between milling element and
screen is very small and velocity distribution is linear,
the average velocity of the grains moving inside the
casing will be 05 v, where v is the peripheral velocity of
the disc in m s
1 (Douglas et al., 1979). It is seen that the
grain adhering to the emery surface exerts inertial force
to the neighbouring grains, while the other grain
revolving in the annular space travels backward to ll
the gap and some tend to fall on the emery surface due
to gravitational force. Therefore, each grain of mass mg
in kg moving at a peripheral velocity v, will have an
angular momentum L in Nm s.

L mg vR

and integrating
Mc 4p2 kB brg o2 R3

10

13
0

Hence, the transfer of momentum L in Nm s between

grains can be estimated as

The energy Ec in J, required to abrade the grain along

the periphery of the emery disc

L0 mg vR
05R0

Ec 4p2 kB brg o2 R3 t

where R0 is the radial distance of the grains present on

the outside periphery, in m.
So power transmitted Pw in W in the process is

11

Pw mg vR
05R0 o

Emery disc

14

15

Energy transfer for a single grain is

Em mg vR
05R0 ot

Steel core

16

The number of grains n present on the emery surface in a

single layer
n 2pRB=Ap

2ro

2R

Spindle for rotation

17

where Ap is the projected area in m2 of a single rice

grain.
Taking an ellipsoidal shape of the rice grain, the
surface area of the rice grain of length l in m and width
w in m can be given as (Selby, 1967)

B+2s

Ap plw=4

18

Polisher screen

Hence,
Fig. 3. Abrasion on the disc peripheral surface: R, radius of the
abrasive wheel; r0, radius of the steel core; B, width of the
abrasive wheel; s, gap between the casing and abrasive wheel

8RB
lw

19

ARTICLE IN PRESS
WEAR OF RICE IN AN ABRASIVE MILLING OPERATION

Hence, total momentum energy Em in J caused by grain

to grain friction is
8RB
mg vR
05R0 ot
Em
20
lw
2.5. Energy balance
Since abrasion and friction cause the surface temperature elevation, the thermal energy of the grain Eh in
J may be expressed as
Eh Mg Cpg Tf
Ti

21

where Mg is the mass of grain in kg; Cpg is the specic

heat of the grain in kJ kg
1 8C; Ti and Tf are the initial
and nal temperatures of the grain in 8C, respectively.
Therefore
Eh
22
Tf
Ti
Mg Cpg
Tf Ti

Eh
Mg Cpg

23

Bran is removed at every stage of milling; thereby, a

linear equation was used to represent the grain mass
retained with respect to time of milling in s, during the
milling operation in a specied milling machine
dMg
Mg
t 0197
01879  10
3 t
24
dt
All the energy factors are time dependent, represented
with respect to time. On energy balance
E E 0 Ea Em Eh

25

where E is the total energy input energy in J and E0 is the

idle energy under no load condition in J.
Eh E
E 0
Ea
Em

26

By using Eqns (23) and (26), the nal temperature of the

grain becomes
E
E 0
Ea
Em
Tf Ti
27
Mg Cpg

3. Materials and methods

Freshly harvested, Swarna, medium grain variety
(procured from local market) was selected for this
study. The variety was dehusked using a Satake rice
dehusker (Type THU, Satake Engineering Co., Tokyo,
Japan) and stored in double-sealed polythene bags at
5 8C in a refrigerator (Quick freezer, 200 L capacity,
Remi equipments, India) till the experimentation.
Samples were removed from the refrigerator 24 h before
the experiments to equilibrate the temperature to room

105

Table 1
Properties of medium grain brown rice
Property
Machine efciency
Specic heat of brown rice, kJ kg
1 8C
Abrasion coefcient
Grain bulk density, kg m
3
Radius of the abrasive roll, mm
Width of the abrasive roll, mm
Length of grain, mm
Width of grain, mm
Thickness of grain, mm
Speed of roll, min
1
Bulk mass of grain, kg
Mass of single grain, mg
Radial distance of the grains present outside
periphery, mm
Radius of the steel core, mm
Radius of the polisher spindle, mm

Value
058
1942
0030
794
76
38
575
226
171
1330
02
157
791
35
12

conditions. Three principal diameters, viz. length, width

and thickness of brown rice of each variety were
measured manually by Satake Grain Shape Tester
(Model-MK 100, Japan) having 0001 mm precision.
Measurements of 50 well-distributed, randomly drawn
grains from the test samples of each variety were made.
Bulk density was determined by weighing 1 L of brown
rice in the USDA test weight apparatus, as specied by
the equipment (Ohaus, USA, precision 00001 kg m
3),
in triplicate. The measurement of specic heat was
carried out using a NETZSCH Differential Scanning
Calorimetry (DSC) software version 3.6. (Phonics,
Germany) (Tang et al., 1991).
The measured dimensions and other relevant properties of brown rice are presented in Table 1. The brown
rice samples (200 g), after cleaning and grading were
polished in an abrasive polisher (Model: Satake PearlerTM05) for 15180 s, at 15 s intervals. The emery size
chosen was 36 grit and at an average rotor speed of
1330 min
1. Power at different durations of milling
(15180 s) was measured using a wattmeter (Automatic
Electrical, Mumbai, India, DVS/1065).
The head rice yield YHR was expressed as the
percentage of the head rice with respect to the brown
rice weight. An average data of triplicate samples were
used for analysis. The temperature rise in the bulk of the
samples during the abrasion was determined using a
digital thermometer (Multispan 6 Channel, 1106, J type
Sensor, range 0600 8C, precision of 01 8C). An average
of ve data points was considered for calculation. The
model developed to predict nal bulk temperature of
grain in an abrasive milling system was validated with
the experimental data.

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D. MOHAPATRA; S. BAL

Model accuracy was measured by the per cent relative

deviation modulus P using the following formula
(Madamba et al., 1996):
n0
jTfpre
Tfobs j
100 X
P 0
n
Tfobs
0

28

where: Tfpre is the nal predicted temperature of the

grain, Tfobs is the observed value of the temperature of
the grain and n0 is the number of data points.

4. Results and discussion

4.1. Temperature rise during milling
The relationship between the nal bulk temperature
of grain Tf and head rice yield YHR was depicted in
Fig. 4. As observed from Fig. 4, it is evident that with
rise in bulk temperature of the grain, the head rice yield
decreases linearly. The mechanical properties (i.e. hardness) change with temperature, thereby making the
material brittle at high temperatures (Juliano, 1985;
Ernest & Porankiewicz, 1999). Since the rice grain is a
starchproteinfat complex polymer, it is likely that the
grain property will alter with rise in temperature. This
results in crack generation, leading to breakage of
grains. As evident from Fig. 4, unit degree rise in
temperature above 35 8C results in additional 15 to
2% broken grains in the experimental range. Thus, a

temperature differential of even 5 8C above ambient can

pose a detrimental effect on the head rice yield by
reducing its value from 81 to 73%, especially for the
fragile indica variety. Therefore, it is essential to check
the milling temperature by grain cooling or maintaining
a lower temperature in the milling environment to check
these thermal stress cracks.
The relationship between the nal grain temperature
and milling duration t under steady-state conditions was
validated and presented in Fig. 5. The mathematical
model developed was a good t for the experimental
data. It was evident from the solution that the heat
generation was greatly affected by the abrasion coefcient of the grain with the milling material under
dynamic conditions. The model gave a maximum
deviation (2 8C) of temperature between the observed
and predicted value. The difference between the
estimated and corresponding measured temperature
may be expected because of the time delay (about 10 s)
in measuring the temperature after the milling operation. Per cent relative deviation modulus was calculated
for the predicted and observed values and it was found
to be less than 3%, which is in the acceptable range
(Madamba et al., 1996). The average error percentage
was 28% indicating a good t of the predicted model
with the experimental data (Cleland et al., 1987). Since
the temperature is a time-dependent factor, the rise in
temperature could be known for a given operating time
of a polisher in a batch process. This model may be
used to design the cooling devices for the polisher. As
the breakage was related to the grain temperature,
the temperature of the grain as well as polisher may

95

YHR = 1.6931Tf + 142.76

COD = 0.982

50

85
80

Final temperature of grain,C

Head rice yield YHR, %

90

75
70
65

45

40

35

60
30

35

40

45

50

Final temperature of grain Tf, C

Fig. 4. Variation in head rice yield with final bulk surface

temperature of grain depicting a linear relationship: ^,
measured final temperature of the grain; COD, coefficient of
determination

30
0

50

100
Time of milling, s

150

200

Fig. 5. Measured (^) and predicted (-) final bulk surface

temperature grain for different milling times

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WEAR OF RICE IN AN ABRASIVE MILLING OPERATION

be regulated to reduce breakage during the milling

operation. In the model, the friction factor plays a major
role in deciding the energy requirement for the operation
(Fig. 6).

for milling/polishing and momentum transfer to grains

during milling.

5. Conclusions
4.2. Energy balance of milling system
It was observed from the performance test on the
polisher that 5560% of the total energy supplied to the
machine is used for rotating the rotor and other machine
components under idle run condition. The energy
utilised to rotate the machine components in idle
conditions in the initial stage was high (60%), which
reduced to 55% on progressive milling conditions
(Table 2). Out of the total energy supplied to the
system, 4512% goes for heating the grain and 3335%

Heating,
10.1%

Abrasion ,
33.4%

Modelling of dynamic abrasion in a rice milling

operation is important in the understanding of the basic
phenomena, as well as for design of suitable polishing
systems to obtain better quality-milled rice. During a
milling operation there is an increase in the bulk surface
temperature of the grain due to abrasion/friction. With
a rise in temperature, the grain experiences thermal
stress, leading to crack generation. This inescapably
results in reduction in head rice yield. The developed
model predicts the rise in temperature of the bulk
samples of rice grain in an abrasive milling operation.
This shows that the energy dissipated in the grain due to
friction/abrasion causes an increase in the bulk temperature in a steady-state condition. The energy balance
gave an estimate of energy utilisation in the milling
operation. More than half of the total input energy to
the system is actually utilised for running the machine
components in idle conditions, and the balance is
utilised for polishing the grain by overcoming friction/
abrasion and carrying the grain weight. The rest of the
energy is dissipated into heat energy, thus rising the
temperature of the grain.

Idle, 56.5%

Acknowledgements

Fig. 6. Pie chart showing distribution of energy in a milling

operation

Assistance received from Dr Amiya Ranjan Mohanty,

Mechanical Engineering Department, Indian Institute
of Technology, is gratefully acknowledged.

Table 2
The input energy to the polishing machine under full load condition and no load condition at different milling times
Milling time (t), s
15
30
45
60
75
90
105
120
135
150
165
180

Energy under full

load (E), kJ

Energy under no
load (E0 ), kJ

Idle energy,
%

Abrasion energy,
%

Heat energy,
%

360
732
1116
1512
1920
2340
2730
3120
3510
3900
4290
4680

216
432
648
864
1080
1296
1512
1728
1944
2160
2376
2592

600
590
581
571
563
554
554
554
554
554
554
554

354
349
343
337
332
327
327
327
327
327
327
327

46
61
76
91
105
119
119
119
119
119
119
119

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D. MOHAPATRA; S. BAL

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