Wear Patterns Research Articles

Impact of tool nose size on the performance and wear behavior of carbide tool when boring 1Cr17Ni2 martensitic stainless-steel parts

Purpose This study aims to examine the cutting performance of a coated carbide tool during the boring of 1Cr17Ni2 martensitic stainless steel, with a focus on how the tool’s structural parameters, particularly the nose radius, affect the wear patterns, wear volume and lifetime of the cutting tool, and related mechanisms. Design/methodology/approach A full factorial boring experiment with three factors at two levels was conducted to analyze systematically the impact of cutting parameters on the tool wear behavior. The evolution of tool wear over the machining time was recorded, and the influences of the cutting parameters and nose radius on wear behavior of the tool were examined. Findings The results show that higher cutting parameters lead to significant wear or plastic deformation at the tool nose. When the cutting depth is less than the nose radius, the tool wear tends to be minimized. Larger nose radius tools have weaker chip-breaking but greater strength and wear resistance. Higher cutting parameters reduce wear for the tools with larger nose radius, maintaining their integrity. Wear mechanisms are primarily abrasive, adhesive and diffusion wear. Furthermore, the full-factorial analysis of variance revealed that for the tool with rε = 0.4 mm and 0.8 mm, the factors contributing the most to tool wear were cutting speed (38.76%) and cutting depth (86.43%), respectively. Originality/value This study is of great significance for selection of cutting tools and cutting parameters for boring 1Cr17Ni2 martensitic stainless-steel parts. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2024-0266/

Numerical Simulation of Flow Fields and Sediment-Induced Wear in the Francis Turbine

Based on the solid–liquid two-phase flow model and the Realizable k-ε Turbulence model, numerical simulations of the sediment–water flow in the flow components of the turbine were conducted. The distribution of sediment-induced wear within the turbine was obtained by analyzing the sediment volume fraction (SVF) and the erosion rate. The results revealed that sediment-induced wear on the stay and guide vanes was primarily distributed along the water inlet edge of the stay and guide vanes. For the runner blades, wear was predominantly localized along the water inlet edge and near the lower ring. The sediment-induced wear patterns on these flow components were found to be consistent with the sediment volume fractions (SVFs) on their surfaces.

Sanding Performance and Wear Mechanism of Precision-Shaped Abrasive Belts for Medium-Density Fiberboard

Sanding in medium-density fiberboard (MDF) often encounters unstable quality and premature failure, primarily because there is currently no abrasive belt specifically suitable for MDF sanding characteristics. We designed two precision-shaped abrasive belts (PSAs) for MDF and herein report on the characteristics. The material removal process for PSA was divided into three phases; the most stable, phase II, represents the effective working period. Compared to the contrast accumulated abrasive belt, PSAs achieve 16.12 and 11.10 times higher surface quality based on the mean value of roughness parameter Sa, achieving 1.34- and 2.0-, and 15.61- and 8.54-times-higher stability in material removal and surface quality based on the mean deviation. Wear patterns on PSAs include large abrasive wear, micro-abrasive fall-off, fracture, and wear, avoiding premature failure due to blockage and promoting long-term and efficient sanding. The uniform shape, height, and distribution of particles in PSAs results in excellent sanding performance. This study provides the foundation for further research on sanding mechanisms and PSA design for MDF.

Hemiarthroplasty in young patients.

The survival of humeral hemiarthroplasties in patients with relatively intact glenoid cartilage could theoretically be extended by minimizing the associated postoperative glenoid erosion. Ceramic has gained attention as an alternative to metal as a material for hemiarthroplasties because of its superior tribological properties. The aim of this study was to assess the in vitro wear performance of ceramic and metal humeral hemiarthroplasties on natural glenoids. Intact right cadaveric shoulders from donors aged between 50 and 65 years were assigned to a ceramic group (n = 8, four male cadavers) and a metal group (n = 9, four male cadavers). A dedicated shoulder wear simulator was used to simulate daily activity by replicating the relevant joint motion and loading profiles. During testing, the joint was kept lubricated with diluted calf serum at room temperature. Each test of wear was performed for 500,000 cycles at 1.2 Hz. At intervals of 125,000 cycles, micro-CT scans of each glenoid were taken to characterize and quantify glenoid wear by calculating the change in the thickness of its articular cartilage. At the completion of the wear test, the total thickness of the cartilage had significantly decreased in both the ceramic and metal groups, by 27% (p = 0.019) and 29% (p = 0.008), respectively. However, the differences between the two were not significant (p = 0.606) and the patterns of wear in the specimens were unpredictable. No significant correlation was found between cartilage wear and various factors, including age, sex, the size of the humeral head, joint mismatch, the thickness of the native cartilage, and the surface roughness (all p > 0.05). Although ceramic has better tribological properties than metal, we did not find evidence that its use in hemiarthroplasty of the shoulder in patients with healthy cartilage is a better alternative than conventional metal humeral heads.

Study of compressor blade wear pattern under transient acceleration

Study of compressor blade wear pattern under transient acceleration

Variation in white‐tailed and mule deer dental metrics is associated with precipitation gradients in the Americas

AbstractInvestigating the relationship between the physical environment and organismal adaptation is crucial to understanding the selective pressures that drive mammalian evolution. Of the varied approaches to exploring this relationship, macroscopic tooth wear analyses have become widely used due to their economic and simple methodologies. However, more work is needed to understand how assessments of wear patterns operate within finer levels of dietary and environmental contexts. It is specifically unclear if and how tooth wear differs inter‐ and intraspecifically between geographically widespread, large‐bodied mammalian populations. This project characterizes molar hypsodonty indices and mesowear scores of white‐tailed deer (Odocoileus virginianus) and mule deer (Odocoileus hemionus) populations across North and Central America, investigating if and how molar wear and morphology vary over the deer's large and ecologically variable geographic distribution. While mesowear scores generally do not strongly track environmental signals within and between Odocoileus species, hypsodonty indices reveal a strong correlation between crown height and aridity, which likely represents an adaptive response to abrasive diets in areas with low precipitation.

Tire wear monitoring using feature fusion and CatBoost classifier

Addressing the critical issue of tire wear is essential for enhancing vehicle safety, performance, and maintenance. Worn-out tires often lead to accidents, underscoring the need for effective monitoring systems. This study is vital for several reasons: safety, as worn tires increase the risk of accidents due to reduced traction and longer braking distances; performance, as uneven tire wear affects vehicle handling and fuel efficiency; maintenance costs, as early detection can prevent more severe damage to suspension and alignment systems; and regulatory compliance, as ensuring tire integrity helps meet safety regulations imposed by transportation authorities. In response, this study systematically evaluates tire conditions at 25%, 50%, 75%, and 100% wear, with an intact tire as a reference, using vibration signals as the primary data source. The analysis employs statistical, histogram, and autoregressive–moving-average (ARMA) feature extraction techniques, followed by feature selection to identify key parameters influencing tire wear. CatBoost is used for feature classification, leveraging its adaptability and efficiency in distinguishing varying wear patterns. Additionally, the study incorporates feature fusion to combine different types of features for a more comprehensive analysis. The proposed methodology not only offers a robust framework for accurately classifying tire wear levels but also holds significant potential for real-time implementation, contributing to proactive maintenance practices, prolonged tire lifespan, and overall vehicular safety.

Influence of particle lithology, size and angularity on rates and products of bedload wear: An experimental study

AbstractPhysical wear during bedload transport influences downstream changes in the size distributions and shapes of riverbed sediment, which in turn affect myriad fluvial processes ranging from incision into bedrock to provision of aquatic habitat. Here we use laboratory tumbling experiments to address several remaining knowledge gaps, including the roles of lithologic susceptibility to fragmentation, particle size distributions and particle angularity in controlling wear rates and the size distribution of wear products. To focus on the dynamics of particle wear in headwater channels, we used initially angular sediment and ran the experiments until 10% of the initial bedload particle mass had been lost to fine‐grained wear products. We measured individual particle mass and diameter by hand and used photo analysis to quantify particle shape and angularity. We find strikingly different wear patterns between limestone and welded tuff. Although wear rates in the tuff were an order of magnitude slower than the limestone, tuff wear was primarily by fragmentation while limestone wear was dominantly by attrition. Fragmentation of the tuff resulted in a widening of the bedload size distribution, a lack of consistent particle rounding and a fine‐wear product dominated by sand. In contrast, limestone particles rounded substantially and produced silt‐sized wear products. Differences in wear product size and susceptibility to fragmentation may reflect contrasts in the size distribution of mineral crystals in each lithology. Wear rates in both rock types declined substantially with increasing cumulative mass loss, due to rounding in the limestone and reduced fragmentation in the tuff. These results suggest that applications of the conventional exponential model to predict mass loss with travel distance need to account for lithologic influence on susceptibility to fragmentation and the influence of rounding on particle wear rates.

Combining experiment and ethnoarchaeology to differentiate the surface conditions of animal hides

There is a wide range of technical processes involved in working animal skins, depending on the environment, the size of the skins and the purpose of the work (clothing, tent covers, etc.). The archaeological tools and their shape, weight, and use-wear are often the only evidence of these technical processes. Their understanding requires an experimental approach combined with ethnoarchaeological data to establish protocols allowing processes compatible with the type of skin to be treated and carry out the correct gestures at each stage of the process. This study, dedicated to the processing of very large hides, presents the experimental replication of the production process of moose hides observed in Canada (B.C.) in an Athaspakan group. The functional analysis of the experimental tools allows identifying different wear patterns corresponding to different surface conditions of animal hides; each of them having particular implications for the interpretation of the archaeological record.

Linear and Volumetric Polyethylene Wear Patterns after Primary Cruciate-Retaining Total Knee Arthroplasty Failure: An Analysis Using Optical Scanning and Computer-Aided Design Models.

(1) Background: Analyses of retrieved inserts allow for a better understanding of TKA failure mechanisms and the detection of factors that cause increased wear. The purpose of this implant retrieval study was to identify whether insert volumetric wear significantly differs among groups of common causes of total knee arthroplasty failure, whether there is a characteristic wear distribution pattern for a common cause of failure, and whether nominal insert size and component size ratio (femur-to-insert) influence linear and volumetric wear rates. (2) Methods: We digitally reconstructed 59 retrieved single-model cruciate-retaining inserts and computed their articular load-bearing surface wear utilizing an optical scanner and computer-aided design models as references. After comprehensively reviewing all cases, each was categorized into one or more of the following groups: prosthetic joint infection, osteolysis, clinical loosening of the component, joint malalignment or component malposition, instability, and other isolated causes. The associations between volumetric wear and causes of failure were estimated using a multiple linear regression model adjusted for time in situ. Insert linear penetration wear maps from the respective groups of failure were further processed and merged to create a single average binary image, highlighting a potential wear distribution pattern. The differences in wear rates according to nominal insert size (small vs. medium vs. large) and component size ratio (≤1 vs. >1) were tested using the Kruskal-Wallis test and the Mann-Whitney test, respectively. (3) Results: Patients with identified osteolysis alone and those also with clinical loosening of the component had significantly higher volumetric wear when compared to those without both causes (p = 0.016 and p = 0.009, respectively). All other causes were not significantly associated with volumetric wear. The instability group differentiated from the others with a combined peripheral antero-posterior wear distribution. Linear and volumetric wear rates showed no significant differences when compared by nominal insert size (small vs. medium vs. large, p = 0.563 and p = 0.747, respectively) or by component (femoral-to-insert) size ratio (≤1 vs. >1, p = 0.885 and p = 0.055, respectively). (4) Conclusions: The study found increased volumetric wear in cases of osteolysis alone, with greater wear when combined with clinical loosening compared to other groups. The instability group demonstrated a characteristic peripheral anterior and posterior wear pattern. Insert size and component size ratio seem not to influence wear rates.

A Contact Mechanics Model for Surface Wear Prediction of Parallel-Axis Polymer Gears.

As surface wear is one of the major failure mechanisms in many applications that include polymer gears, lifetime prediction of polymer gears often requires time-consuming and expensive experimental testing. This study introduces a contact mechanics model for the surface wear prediction of polymer gears. The developed model, which is based on an iterative numerical procedure, employs a boundary element method (BEM) in conjunction with Archard's wear equation to predict wear depth on contacting tooth surfaces. The wear coefficients, necessary for the model development, have been determined experimentally for Polyoxymethylene (POM) and Polyvinylidene fluoride (PVDF) polymer gear samples by employing an abrasive wear model by the VDI 2736 guidelines for polymer gear design. To fully describe the complex changes in contact topography as the gears wear, the prediction model employs Winkler's surface formulation used for the computation of the contact pressure distribution and Weber's model for the computation of wear-induced changes in stiffness components as well as the alterations in the load-sharing factors with corresponding effects on the normal load distribution. The developed contact mechanics model has been validated through experimental testing of steel/polymer engagements after an arbitrary number of load cycles. Based on the comparison of the simulated and experimental results, it can be concluded that the developed model can be used to predict the surface wear of polymer gears, therefore reducing the need to perform experimental testing. One of the major benefits of the developed model is the possibility of assessing and visualizing the numerous contact parameters that simultaneously affect the wear behavior, which can be used to determine the wear patterns of contacting tooth surfaces after a certain number of load cycles, i.e., different lifetime stages of polymer gears.

Comprehensive Analysis of Needle Bearing Failures in Fuel Transfer Pumps: Insights from Testing and Finite Element Analysis

<div>This study investigates the failure mechanisms of needle bearings within fuel transfer pump assemblies through a comprehensive approach combining endurance testing, detailed inspection, the Dykem blue method, proximity sensors, and finite element analysis (FEA). The findings reveal critical insights into the causes of failure, highlighting significant axial displacement, with a maximum of 0.37 mm measured by proximity sensors. The Dykem technique identified distinct wear patterns across various components, pinpointing areas of high stress and potential failure. Detailed bearing inspections uncovered trunnion damage and abrasive wear, corroborated by FEA, which quantified displacements of 0.144 mm in the x-direction, 0.030 mm in the y-direction, and 0.015 mm in the z-direction. The primary operational factors contributing to bearing failure were contamination and inadequate axial control. These insights are pivotal, as they align with and expand upon established literature on bearing failures, providing a deeper understanding of the interplay between mechanical wear and operational conditions. Despite the robustness of the methodology, challenges included ensuring the accuracy of axial displacement measurements and replicating real-world operational stresses in a controlled environment. The study proposes several recommendations to enhance axial support and optimize system design to mitigate the identified issues. The societal impact of this research is significant, offering potential improvements in machinery reliability, which can lead to enhanced industrial efficiency and safety standards. This work advances the current knowledge in the field and provides practical solutions for extending the lifespan and performance of critical mechanical components in fuel transfer systems.</div>

Unlocking the potential of wearable device wear time to enhance postpartum depression screening and detection.

Postpartum depression (PPD) is a mood disorder affecting one in seven women after childbirth that is often under-screened and under-detected. If not diagnosed and treated, PPD is associated with long-term developmental challenges in the child and maternal morbidity. Wearable technologies, such as smartwatches and fitness trackers (e.g., Fitbit), offer continuous and longitudinal digital phenotyping for mood disorder diagnosis and monitoring, with device wear time being an important yet understudied aspect. Using the All of Us Research Program (AoURP) dataset, we assessed the percentage of days women with PPD wore Fitbit devices across pre-pregnancy, pregnancy, postpartum, and PPD periods, as determined by electronic health records. Wear time was compared in women with and without PPD using linear regression models. Results showed a strong trend that women in the PPD cohort wore their Fitbits more those without PPD during the postpartum (PPD: mean=72.9%, SE=13.8%; non-PPD: mean=58.9%, SE=12.2%, P -value=0.09) and PPD time periods (PPD: mean=70.7%, SE=14.5%; non-PPD: mean=55.6%, SE=12.9%, P -value=0.08). We hypothesize this may be attributed to hypervigilance, given the common co-occurrence of anxiety symptoms among women with PPD. Future studies should assess the link between PPD, hypervigilance, and wear time patterns. We envision that device wear patterns with digital biomarkers like sleep and physical activity could enhance early PPD detection using machine learning by alerting clinicians to potential concerns facilitating timely screenings, which may have implications for other mental health disorders.

High Temperature Wear Property of Ta-10W Alloy

This study investigated the high-temperature wear characteristics of Ta-10W alloy, composed of 90% tantalum and 10% tungsten, known for its high melting point, excellent corrosion resistance, and oxidation resistance. Wear tests were conducted using a ball-on-disc method with alumina balls at temperatures of 200°C, 400°C, 600°C, and 700°C. The results indicated that wear loss decreased (increasing wear resistance) from 200°C to 600°C due to the lubrication effect by oxide particles induced by Ta2O5, which enhanced wear resistance. However, at 700°C, a significant increase in wear loss was observed due to excessive oxide formation and the occurrence of cracks. Calculation of the wear rate revealed that it decreased as the temperature increased to 2.12×10-4 mm3· N-1· m-1 at 200 °C, 2.67×10-5 mm3·N-1·m-1 at 400 °C, and 4.21×10-6 mm3· N-1· m-1 at 600 °C. On the other hand, the wear rate increased at 700 °C to 3.87×10-4 mm3· N-1· m-1. The wear track analysis results revealed distinct wear mechanisms at different temperatures. At 200°C, abrasive wear characterized by pits and furrows was dominant. At 400°C, adhesive wear became more prevalent with cleavage worn surfaces compared to the wear pattern at 200°C. At 600°C, fragmented oxides indicating pest oxidation were noted, while at 700°C, deep pits and cracks along with fragmented oxides were prevalent. X-ray diffraction (XRD) analysis results showed the presence of the α-Ta phase at 200°C, 400°C, and 600°C, with peak shifts indicating lattice expansion. In contrast, at 700°C, Ta2O5 peaks were present. Based on the findings, the high-temperature wear mechanism of Ta-10W alloy was also discussed.

Ten-year clinical and radiological outcomes with a vitamin E-infused highly cross-linked polyethylene acetabular cup.

Limited implant survival due to aseptic cup loosening is most commonly responsible for revision total hip arthroplasty (THA). Advances in implant designs and materials have been crucial in addressing those challenges. Vitamin E-infused highly cross-linked polyethylene (VEPE) promises strong wear resistance, high oxidative stability, and superior mechanical strength. Although VEPE monoblock cups have shown good mid-term performance and excellent wear patterns, long-term results remain unclear. This study evaluated migration and wear patterns and clinical and radiological outcomes at a minimum of ten years' follow-up. This prospective observational study investigated 101 cases of primary THA over a mean duration of 129 months (120 to 149). At last follow-up, 57 cases with complete clinical and radiological outcomes were evaluated. In all cases, the acetabular component comprised an uncemented titanium particle-coated VEPE monoblock cup. Patients were assessed clinically and radiologically using the Harris Hip Score, visual analogue scale (pain and satisfaction), and an anteroposterior radiograph. Cup migration and polyethylene wear were measured using Einzel-Bild-Röntgen-Analyze software. All complications and associated treatments were documented until final follow-up. Clinical assessment showed persistent major improvement in all scores. On radiological assessment, only one case showed a lucent line (without symptoms). At last follow-up, wear and migration were below the critical thresholds. No cup-related revisions were needed, indicating an outstanding survival rate of 100%. Isoelastic VEPE cups offer high success rates and may prevent osteolysis, aseptic loosening, and the need for revision surgeries in the long term. However, longer follow-up is needed to validate our findings and confirm the advantages offered by this cup.

Quantitative evaluation of pyramid belt wear using light-reflection characteristic of agglomerate coating and image processing

As a new generation of coated abrasive products with a unique pyramid-shaped structure, pyramid belt offers finer and more uniform grinding effects, and has been increasingly applied in precision grinding. However, belt wear occurs inevitably, challenging the control of shape accuracy and surface quality of ground components. Current research on pyramid belt wear is relatively limited, still lacking a universal, rapid method for observing and evaluating belt wear. In response, this paper proposes a quantitative evaluation method for pyramid belt wear using light-reflection characteristic of agglomerate coating and image processing. Firstly, a detailed analysis of the wear types and characteristics of pyramid belt is conducted. Then, focusing on the agglomerate flat wear, a method utilizing the light-reflection characteristic of agglomerate coating for observing belt wear morphology is proposed, enabling clear image capture of belt wear contours. Based on this, a wear coefficient based on the geometric characteristics of agglomerate is defined, and a quantitative evaluation method for belt wear using image processing is further proposed. The wear experiment of the belt is conducted on a robotic belt grinding platform, and experimental results show that the evaluation deviation of the proposed method from the evaluation results based on optical profilometer is within 5% at a 95% confidence interval, demonstrating the effectiveness of this method. Additionally, this method has advantages such as high computational efficiency, low cost, and good usability. Finally, the temporal evolution processes and spatial distribution patterns of belt wear and material removal rate are investigated and analyzed.

Effect of Grinding Media Grading on Liner Wear and Load Behavior in a Ball Mill by Using Rocky DEM

The liner is a wear-prone component in ball mills, subject to continuous impacts, squeezing, and abrasion from the grinding media during operation. Its service performance directly affects the working efficiency of the ball mill. The service life of mining ball mill liners is about 8 months, and frequent downtimes occur due to liner wear and loss of effectiveness, with liner replacement accounting for about 6% of the total cost, resulting in huge economic losses. This paper focuses on a Φ305 mm × 150 mm experimental ball mill, using the discrete element software Rocky Discrete Element Method (DEM) (software version number Rocky 2022 R2) for simulation modeling analysis. With Φ10 mm and Φ20 mm mono-size particle simulations serving as reference groups, this study investigates the motion states and liner abrasion patterns under different liner heights for both sizes of grinding media in Equilibrium Quality Manufacturer (EQM) and Original Equipment Manufacturer (OEM) gradations. The results indicate that the impact of liner height on the wear of the ball mill liners is related to the size and gradation of the grinding media. The degree of liner wear from highest to lowest is as follows: EQM > Φ20 mm > OEM > Φ10 mm. Due to the effect of the cylinder end cap, the wear at the axial center of the ball mill liner is more severe than at both ends, and the wear on the facing side of the liner is more severe than on the backside. A thorough study of the influence of ball mill grinding media gradation on the wear pattern of liners is of great theoretical significance for optimizing liner structures, improving grinding efficiency, and promoting energy saving and cost reduction in ball mills. This study provides theoretical guidance for understanding the mechanisms behind liner wear in ball mills and predicting the liner lifespan.

Investigation on the performance of spark plasma sintered ultrafine WC-Co cemented carbide end mills during high-speed precision milling of Ti-6Al-4V alloy

In this study, ultrafine WC-Co and WC-(Ti,W)C-Co cemented carbide end mills were fabricated via spark plasma sintering. The performance of those tools in the high-speed precision machining of Ti-6Al-4V alloy was investigated, focusing on the analysis of tool wear mechanisms, cutting performance, and machined surface roughness. The results reveal that adhesive wear emerges as the predominant wear mechanism influencing the performance of both tools. The addition of (Ti,W) C leads to high workpiece element enrichment on the flank face of the tool, increasing subsequently severe adhesive wear. WC-(Ti,W)C-Co displays a greater propensity for crack propagation and material chipping, culminating in premature tool failure with the formation of significant wear craters and cutting edge breakage. Conversely, WC-Co exhibits comparatively milder wear patterns and a reduced incidence of cutting edge chipping due to its inherent resistance to adhesive wear. Additionally, the comparison of the developed ultrafine cemented carbide tools with similar commercial tools demonstrates that WC-Co has superior cutting performance in terms of tool life, 1.5–1.8 times longer than the commercial tools. These findings provide guidance for optimizing machining strategies and developing advanced tool materials for high-speed milling titanium alloy.

Synergistic regulation of microstructure, properties, and abrasive wear mechanism of a medium carbon dual phase steel for plowshares

In this study, a new medium carbon dual phase (DP) steel for plowshares is prepared. The quenching and partitioning process of the medium carbon steel is designed and optimised using the constrained carbon equilibrium model. The optimised process parameters are quenching temperature of 880 °C, quenching bath temperature of 190 °C and partitioning temperature of 350 °C. The microstructure of the acicular martensite matrix with 13% retained austenite was prepared, so that the good mechanical properties of tensile strength of 2007 MPa, yield strength of 1689 MPa, elongation of 11% and impact energy of 12 J are obtained. The multi-scale characterisation and abrasive wear experiments are carried out to investigate its microstructural evolution and wear mechanism under simulated working conditions. The results show that the coordinated deformation of retained austenite and martensite, as well as the trip effect, endows it with ultra-high strength and good plasticity. The recurring process of formation and spalling of the hardened layer is the main wear pattern of this medium carbon DP steel. The synergism of twinning formation and (Ti, Mo)C precipitation enhances wear resistance of this medium carbon DP steel.

Research on the Wear State Detection and Identification Method of Huller Rollers Based on Point Cloud Data

Throughout the huller shelling process, the rubber rollers progressively deteriorate. The velocity of the rubber rollers decreases as the distance between the rollers rises. These modifications significantly influence the rate at which rice hulling occurs. Hence, the implementation of real-time online detection is crucial for maintaining the operational efficiency of the huller. Currently, the prevailing inspection methods include manual inspection, 2D vision inspection, deep learning methods, and machine vision methods. Nevertheless, these conventional techniques lack the ability to provide detailed information about the faulty components, making it challenging to conduct comprehensive defect identification in three dimensions. To address this issue, point cloud technology has been incorporated into the overall detection of the working condition of the huller. Specifically, the Random Sample Consensus segmentation algorithm and the adaptive boundary extraction algorithm have been developed to identify abnormal wear on the rubber rollers by analyzing the point cloud data on their surface. A solution technique has been developed for the huller to compensate for the speed of the rubber rollers and calculate the mean values of their radii. Additionally, a numerical simulation algorithm is proposed to address the dynamic change in the roller spacing detection. The results show that point cloud data can be utilized to achieve real-time and precise correction of anomalous wear patterns on the surface of rubber rollers.