Ball mills used in the mineral processing industry grind input ore int
o finer output. However, during this grinding process, ball mill eleme
nt wear affects grinding performance. In this article, wear models are
developed in order to determine how a ball charge size distribution a
nd liner profiles change as a result of wear. Specifically, it was pos
sible to model and then to simulate ball charge and liner wear, two fa
ctors that determine ball mill non-stationary behaviour, using results
from a ball charge motion model. The ball charge wear model incorpora
tes adhesive and abrasive wear as a function of energy dissipated in c
rushing, tumbling and grinding zones of the charge motion profile. The
liner wear model incorporates abrasive wear with centrifugal and grav
itational forces acting on mill liners. Simulation results shows how a
ball size distribution evolves in time as well as how two different l
iner profiles change over time. These results allow for further work i
n ball mill optimization as a function of this non-stationary mill beh
aviour.