Mechanical Performance Analysis of Key Components of Segmented Roller-Sleeve Assembly for High-Pressure Grinding Roll

High-pressure grinding rolls (HPGRs) are widely used in energy-efficient comminution, and the structural reliability of their load-bearing assemblies is important for stable operation and service life. However, the mechanical response and weak-component behavior of segmented roller-sleeve assemblies under combined preload, radial pressure, torque, and frictional contact remain insufficiently understood. In this study, a three-dimensional finite-element model of a segmented roller-sleeve HPGR was established, incorporating frictional contact, bilinear isotropic hardening, and stepwise loading. The study focuses on the coupled mechanical response, identification of critical weak components, preload relaxation, and parameter sensitivity of the assembly. The results show that stress concentration mainly occurs at geometric discontinuities and local contact regions, with the square washer identified as the principal weak component. Local yielding of the washer may cause preload relaxation without immediate loss of the overall clamping function. Material and thickness optimization can effectively improve washer strength, while friction and pressure-distribution assumptions mainly influence local stress redistribution. These findings provide guidance for strength evaluation and structural optimization of segmented roller-sleeve HPGR assemblies.