The progress of human technology has led to the development of the whole mining industry. Steel balls have become the necessary products for the crushing and grinding of mines in the world.
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There are three kinds of steel ball manufacturing process: forging, rolling and casting.
Casting: The quality of cast steel balls mainly depends on the content of chromium. In recent years, the price of chromium has been rising, and environmental protection factors have led to the increasing cost of cast steel balls.
Forging: Using high manganese steel as raw material, and using pneumatic forging hammer with spherical die to make the steel balls. It has the characteristics of small investment and quick start, but high dependence on human beings.
Rolling: Using high manganese steel bar as raw material, and using the rolling mill with special spiral hole die to make steel balls. The production efficiency and automation degree is high, but the investment cost is also high.
On the premise of equal raw materials, contrastive analysis of steel ball quality produced by different manufacturing technologies are as follows:
Casting＜Rolling＜Forging
Cast steel ball
Cast steel balls are naturally solidified by molten steel, which will inevitably lead to internal structure loosening, porosity and other defects, which will lead to brittle, eccentric wear and loss of circle in the use of steel balls. So most of grinding steel balls used in mine are forged steel balls and rolled steel balls. Next I will go into process and machine of forged steel balls and rolled steel balls, as well as a new steel ball manufacturing process and production line.
Traditional forged steel balls use air hammer to forge raw materials to a certain amount of deformation, increase compression ratio, so as to make the structure of wear-resistant balls more compact, improve toughness and hardness. Because forged steel balls have all the attributes of forgings, the quality of forged steel ball is the best among all of these steel ball manufacturing processes.
Pneumatic hammer forging is a traditional forging method for steel ball making. The steel ball forging process is shown as follow:
Heat the steel bar in medium frequency induction furnace - cut the steel bar by billet hot shearing machine - pre-forging on pneumatic forging hammer - final forging on pneumatic forging hammer - heat treatment
In this process, in order to increase the forging efficiency, there are one hammer for pre-forging and another hammer for final forging. Actually, one hammer can also achieve the whole forging.
Pneumatic forging hammer is suitable for various of steel balls, especially those steel balls with large diameter and super large diameter. It can forge steel ball with wide range of diameters on one hammer, flexible process, suitable for various batches of production.
steel ball pneumatic forging hammer and forging robot
The special pneumatic forging hammer for steel ball making has been promoted at the basis of traditional pneumatic forging hammer, adding pedal device, all of the hammer can operated by one people. In order to increase the reliability, the working cylinder of pneumatic power forging hammer adopts prestressed structure, the hammer rod adopts circular shape, in order to increase its strength.
The skew rolling technology is a leap forward development in the forging steel ball industry. The bar used for rolling is rolled, so the structure of the ball is relatively uniform. However, the rolling process only cuts and rubs the bar, which does not meet the requirement of forging ratio, so it does not have the properties of forging. Rolling ball process is with a high degree of automation, the production efficiency is much higher than the forged steel ball line, it can produce the steel balls below φ125mm, rolling ball line is also used in mass production, high requirements on the workshop.
Steel ball skew rolling mill is a ball automated production equipment, suitable for the production of steel balls with various materials: carbon steel, manganese steel. The rolled steel balls are widely used in mines, steel mills, chemicals, building materials, cement, metallurgy, thermal power plants and other industries, with automatic heating equipment and transmission equipment, realized automated production.
Heat the whole steel bar in medium frequency induction - continuous rolled on skew rolling mill - heart treatment
The skew rolling technology does not need blanking and air hammering, which greatly improves the production efficiency, greatly reduces the labor intensity of workers, and greatly reduces the hazards of noise and other hazards.
Forging-rolling technology is a new steel ball manufacturing process developed by Anyang Forging Press. Forging and rolling process can theoretically produce steel balls of various diameters, but due to investment and efficiency reasons, it is usually used to mass produce steel balls with diameters of 100-200 mm, which has achieved better investment returns.
Medium frequency induction furnace - billet hot shearing machine - robot - automatic forging hammer - rolling mill - heat treatment
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After the bar shear is heated by the medium frequency heating furnace, the heated bar is cut off by the bar shear machine according to the required length. After material selection and distribution, the qualified material is sent to the NC hammer by the robot. The pre-forging is carried out on the NC hammer. After the pre-forging, the ball is basically formed. With the cooperation of the cylinder, the ball is rolled into the steel ball roller circular machine through the material trough. The steel balls with good appearance are produced by competitive rolling of ball roll mill. After subsequent heat treatment, high hardness wear-resistant steel balls can be obtained.
skew rolling mill for steel ball making
billet shearing machine
Anyang Forging Press can provide the machine involved in the above three kinds of steel ball manufacturing process. Pneumatic power forging hammer, skew rolling mill, and other assistant machine for forging automation, such as medium frequency heating furnace, heat treatment machine, forging robot, transmission equipment, etc. If you have any needs in steel ball manufacturing process, please feel free to contact us.
The steel ball manufacturing process can be roughly divided into three types: casting, rolling and forging.
Casting Steel Ball Manufacturing Process
Due to the natural solidification of molten steel, the cast steel balls will inevitably have defects such as loose internal structure and air holes after forming, which will lead to brittle, eccentric wear and out of round phenomena in the use of steel balls. The quality of cast steel ball mainly depends on the content of chromium. In recent years, the price of chromium has gone up all the way and environmental protection and other factors have led to the increasing cost of cast steel ball.
Forging Steel Ball Manufacturing Process
Using high manganese steel as the raw material, using air hammer to install the spherical mold for forging, which has the characteristics of small investment and fast starting, but high dependence on people.
The forged steel ball has all the attributes of forging, so the quality is the best in these kinds of steel ball manufacturing processes. Generally, the steel ball making machine used is air hammer, which has the advantages of small investment and fast starting, but it has strong artificial dependence and low production efficiency.
The surface quality of the forged steel ball, the impact resistance, and the wear resistance are all good, the toughness is strong, and it is not easy to be broken and loss round. We use forging and press methods, which can heat the metal until the temperature reaches ºC(±50ºC), and use the forging machine to apply pressure to the metal blank to plastically deform it to obtain the forging with certain mechanical properties, shape and size. method.
Through forging, defects such as as-cast looseness caused by metal in the smelting process can be eliminated, optimize the microstructure, and at the same time, the mechanical properties of the forgings are generally better than those of the same materials due to the preservation of the complete metal flow lines.
Forged steel balls are precise in size, high in roundness, high in hardness, and have mechanical properties. It is wear resistant, not easily deformed and broken. It can be fully reflected by the high hardness. The surface hardness is as high as 57hrc to 67hrc, the volume and hardness are as high as 56hrc to 64hrc, the hardness distribution is uniform, the impact toughness is more than 12j/cm2, the breakage rate is low, and the anti-fatigue drop test is more than 20,000 times. The actual damage is caused. The rate is no more than 1%, close to 0.
We have made a comparison between the cast steel ball and our forged steel ball. The results of the two are 0.9kg/t and 0.6kg/t respectively in domestic iron mines. From the data, we can see that using forged steel balls, the consumption of one ton of ore is reduced by 33.3%.
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Rolling Steel Ball Manufacturing Process
Using high manganese steel bar as raw material and using the rolling mill with special spiral hole mould for production, the production efficiency is high, the automation degree is high, but the investment cost is also high.
The bar used for rolling the ball is rolled, so the structure of the ball is relatively uniform. However, the rolling process only shears and rubs the bar, which does not meet the requirements of forging ratio, so it does not have the properties of forging completely. The production equipment used is the production line of steel ball skew rolling mill, which has the characteristics of high production efficiency and full-automatic production.
more inroduction of roll steel balls.
Quality compare between different Process
In same raw material, the quality comparison and analysis of steel balls produced according to different steel ball manufacturing processes are as follows:
(b)Casting < rolling < forging.
Forging & Rolling Line - A New Steel Ball Manufacturing Process
Although the quality of forged steel ball is good, but ouput is low and rely on much of labor. In order to solve this problem, Anyang Forging Press has developed the technology of forging-rolling by combining forging automation with practical experience of steel ball production. The process combines the characteristics of forging and rolling steel balls, and takes CNC die forging hammer or electric screw press as the core steel ball making machine, matching bar cutting machine, forging manipulator, rounding machine and other equipment to achieve full-automatic and efficient production of forged steel balls.
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