Mining excavators play a crucial role in the mining industry, and their reliable operation depends on the integrity and efficiency of various components, including rollers and pins. This study presents a comprehensive analysis of mining (Bucket wheel) excavator rollers and pins, aiming to understand their structural characteristics (load capacity and structural integrity), performance, deformation, and failure behaviour as well as potential areas of improvement. The study investigates the performance aspects of excavator rollers and pins in terms of their ability to withstand compressive pressure forces employing Finite Element Modelling (FEM). Numerical studies, in conjunction with experimental validations, are found to be capable of determining stress distribution as well as failure criteria of bottom roller and pin. A thorough quasi-static analysis has been conducted, considering the real-world operating conditions of the excavator. The simulation findings are found to be helpful towards extending maintenance windows, decreasing failures, and improving the roller and pin system efficiency. FE simulations reveal that increased velocity significantly raises von Mises stress and contact pressure, with the highest values at 1.0 m/s, and causes the roller's principal stress to shift from compressive to tensile. Optimal operational parameters are found to be excavator roller translational velocity of 0.75 m/s and an applied pressure load of 200 MPa. Whereas metallographic, chemical analysis, and mechanical characterisation of the failed roller and pin samples establishes the metallurgical reasons of failure of roller-pin assembly, apart from confirming accuracy of the simulation findings. Also, the strain softening from dynamic and static overloading is identified as the main cause of failure mechanism. Fracture surface analysis shows ductile failure in pins and mixed-mode fracture in rollers.
