Nails
| Application: | Mining, Cement Plant, Power Station, Chemical |
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| Standard: | BS, GB, ASTM, ASME, DIN, JIN, EN |
| Hardness: | HRC 50-65 |
| Diameter: | 20mm - 120mm |
| Material: | Cr: 11-14; Cr15-17; Cr16-20 |
| Packaging: | Jumbo Bags, Steel Drums |
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Item |
Hardness |
Impact Value |
Cement Mill Wear (g/mt) |
Typical Applications |
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High Cr Cast Iron |
≥HRc60 |
≥4J |
25-60 |
The dry-grinding process in cement works, power plants and wet-grinding process in mine |
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Low Cr Cast Iron |
≥HRc46 |
≥3J |
≤130 |
The dry-grinding process in cement works,power plants and wet-grinding process in mines |
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Composition(%) |
C |
Si |
Mn |
Cr |
P |
S |
Hardness(HRC) |
Wear Rate in Gold Mine |
|
Low Cr Cast Balls |
2.0~3.5 |
≤1.5 |
≤1.0 |
1.5~2.5 |
≤0.07 |
≤0.07 |
46~55 |
About 1000g/MT |
|
Mid Cr Cast Balls |
2.0~3.5 |
≤1.5 |
≤1.0 |
4.0~6.0 |
≤1.0 |
≤1.0 |
≥50 |
About 870g/MT |
|
Cr10 Cast Balls |
2.0~3.3 |
≤1.2 |
≤1.0 |
10~12 |
≤0.05 |
≤0.05 |
≥55 |
≤870g/MT |
|
Cr14 Cast Balls |
2.0~3.3 |
≤1.2 |
≤1.0 |
14~16 |
≤0.05 |
≤0.05 |
≥58 |
|
|
Cr18 Cast Balls |
2.0~3.3 |
≤1.2 |
≤1.0 |
18~20 |
≤0.05 |
≤0.05 |
≥60 |
≤760g/MT |
|
Cr20 Cast Balls |
2.0~3.3 |
≤1.2 |
≤1.0 |
20~26 |
≤0.05 |
≤0.05 |
≥60 |
≤750g/MT |
Details
Forged Steel Grinding Balls
Steel Balls in grinding media have excellent surface quality, toughness and resistance to impact. They are mostly used in metallurgy and gold mining for grinding the ores by enrichment of extracted raw materials in drum mills. In addition, they are also used for the preparation of pulverized coal and many more applications.
What are Forged steel balls used for?
Steel balls are used in rolling mechanisms in rotary motion components such as bearings, while in Grinding media it is mostly used in the mining and cement industry, mostly used in a ball mill to pulverize or mix materials such as chemicals, paints, ceramics, and ores.
Forged Steel Balls are used in gold mining and metallurgy to grind ores. They are also used to extract and enrich raw materials in drum mills. These balls are also applicable in preparing pulverized coal, paints, and ceramics.
Commercially, forged steel balls are used as a rolling mechanism in the rotary motion components of ball mills. It is also used in the production of cement.
How are Steel Grinding Balls Manufactured?
Steel Grinding Balls are manufactured from steel and steel alloys through the rigorous process of hot-rolling, forging, and stamping. The metal is heated up to 1050° C with super wear resistance material and then shaped into perfect spheres with heavy pressure machinery.
How Do You Make A Steel Ball?
There are various processes involved in the making of steel balls. They include;
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The Slug
Steel balls are made from steel rods or wire. This process can cut the steel rod or wire into pieces called slugs. The volume of steel used is a little bit larger than the finished product. Excess materials are removed in the subsequent stages. The steel rod or wire is not yet hardened and therefore malleable.
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Heading
The Slug is now fed to a header machine wherein the balls are put through heading, a cold-forming process. In the heading, the Slug is shaped under pressure by being placed in-between two semi-spherical-shaped containers. The heading process helps form the Slug into a raw ball. However, there are still some excess materials that still need to be removed.
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Flashing
The excess materials present during the heading process are called burrs or flash and must be filed. The filing is done during flashing and can also be called filling. Flashing helps remove the burrs, yet the steel ball is not yet properly rounded, and the metal is not yet hardened.
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Soft Grinding
The steel balls would then go through the soft grinding procedure. The procedure is referred to as soft because the steel balls are not properly hardened yet. This process is somewhat similar to the flashing procedure, except an abrasive grinding stone is used instead of metal plates.
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Heat-Treating
The excess materials in the steel balls have been removed and are properly rounded. They are now put through the Heat-Treating process so they would harden and strengthen. The steel balls would now be heated to around 1500°F and then oil bathed. The manufacturer would now reheat the steel balls at a lower temperature of 325°F and properly harden the ball.
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Descaling
After heat treatment, the steel balls would be discolored and covered in oxide deposits. The manufacturer would put the balls through a process called Descaling to remove the oxide deposits. Descaling uses a chemical agent, mostly an acidic compound, to remove the oxide deposits on the balls.
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Grinding
Now that the steel balls are hardened and rounded, the next step is to grind the steel balls to improve their shape. This process is similar to soft-grinding. The balls are rolled in between a grinding wheel and a steel plate.
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Lapping
The last process is called lapping. Lapping is a process that assists in improving the surface of the steel balls and helps remove small residues so that the steel balls can attain the required tolerance. The balls are placed between two steel plates, one rotating and the other stationary, and rolled to attain a perfect shape and finish.
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Washing
The manufacturing procedure is now completed. The balls are then washed to remove any residue left during the process.
What are the advantages of a ball mill?
- Ball mills produce very fine powder (particle size less than or equal to 10 microns).
- Acceptable for milling toxic materials since it can be used in a completely enclosed form.
- Has a wide application.
- Available for continuous operation.
What Are Grinding Balls Made For?
Grinding balls are used in ball mills to grind the material into powder. Industries can also use grinding balls to mix various materials such as paints, chemicals, ores, and ceramics.
Grinding Balls are made primarily for use in industries and mining. Grinding Balls are used in mining to break down materials such as cement, rock, and stone, while metals and ores are extracted.
What is the working principle of a ball mill?
The ball mill is made up of a hollow section that spins down either a horizontal or a vertical axis. The section is packed with balls. The materials to be crushed are added and the balls move around inside the mill, colliding with the materials The two working principles of a ball mill are the impact and attrition size reduction. The result of the grinding depends on the materials used, size of mill and size of the materials inside the mills.
What Are Ball Mill Balls Made Of?
The materials used in making ball mill balls, also known as grinding media balls, can be classified into three main segments;
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Steel Grinding Media
These are balls made using carbon steel to produce raw material, doped with different chemical elements to possess grinding media properties such as strength and hardness.
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Cast Iron Grinding Media
These types of ball mills make use of cast iron for production.
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Ceramic Grinding media
As its name suggests, this ball mill ball is made of ceramic and used mainly in small mills to produce food and chemicals.
What Are Steel Grinding Balls?
Steel Grinding balls are made using carbon steel as the raw material during production. Steel grinding balls have high resistance to abrasion and lower wear rates. Steel balls are doped with various chemicals to ensure they possess the required hardness and strength.
Steel grinding balls are often used in mining and various other industries.
What Is Grinding Media Used For?
Grinding media are used in various industries and serve interesting processes. Grinding Media is used for crushing or grinding materials in a mill. Grinding Media has various forms, such as soda lime glass, ceramic cylinders, and alumina oxide balls.
How to Measure the Performance of Grinding Steel Balls?
The effectiveness of steel balls is determined by calculating the efficiency of the ball mill which considers multiple factors. The power per tonne of the ball mill is determined by the ball mill fill rate. Good Steel balls will have:
- Greater hardness
- Greater endurance and wear resistance
- Smooth surface
- The low circle loss rate
How Fine Can A Ball Mill Grind?
In some plants, the ball mill can grind the material to about 100 mesh leaving a tube mill to finish the grinding to 200 mesh or even finer. In other plants, the ball will grind the materials totally, but it has to be fed fine ore to ensure its functions properly.
How to Choose Grinding Steel Balls?
The selection of grinding steel balls depends on the hardness and coarse particle size of the ore material. Harder material requires a steel ball of larger diameter for greater impact force.
How many balls are in a ball mill?
The balls inside a ball mill must not exceed 30–35% of its volume. Productivity of ball mills depends on drum diameter and the relation of drum diameter and length.
Why are different size balls used in ball mills?
The ball size is an important factor to determine the mill performance of ball mills. The larger balls are used for the effective breakage of large-size particles, and smaller balls are more effective for the breakage of fine particles.
What Are The Three Types Of Grinding Media Commonly Used in Ball Mills?
Grinding media used in ball mills are selected depending on the materials used. Here are three of the most used grinding media in ball mills;
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Porcelain Balls
Porcelain balls are said to be the most popular Grinding media type. Porcelain balls rarely crack or chip during grading due to their incredible density. Although they are a little bit more expensive than others, their duration of use is worth the extra expense.
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Alumina Oxide Balls
Recently, alumina Oxide balls have gained popularity in ball milling. Their corrosion resistance and degree of abrasion are enviable. Alumina Oxide Balls can withstand extremely high temperatures, which has made these balls one of the highest demands of grinding media.
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Flint Pebbles
Despite being the oldest grinding media, Flint Pebbles remains popular. Even though they are not as durable as porcelain balls, flint pebbles are resilient, can be used with almost all lining types, and are affordable. Flint pebbles are also known for their low material contamination rate.
Forged vs casting
Forged steel is generally stronger and more dependable compared to casting and plate steel. This is mainly because the impact of forging changes the grain flows of the steel creating a superior toughness compared to alternative methods of steel casting. Therefore, Grinding steel balls deal with materials too hard for cast iron balls.
How to test Cast iron Balls?
Before any product is ready to sell, there is a quality inspection test that occurs. This consists of:
- Dropping test
- Hardness test
- Chemical Element Analysis
- Impact Value Test
Why should I import steel from china?
- Steel quality, Governments from importing countries enforce extra measures to ensure quality of imported steel, with rigorous regulations and high quality standards an experienced manufacturer will ensure you have the best quality steel available!
- Steel cost, high production costs and high competition makes buying steel from local suppliers to be more expensive, buying straight from manufacturers like camasteel will cut the cost due to reduction in supply chain.
- Steel Availability, China is known to be the manufacturing capital of the world and is a staple for bulk purchases all over the world. With top steel production houses being based in china, buying and shipping steel cannot be easier.
Delivery of steel products
Forged Steel Grinding balls are shipped in bags of 2000kg in Steel drums. Our steel can be shipped in bulk to any port nearest to you. Before any export, we make sure to test random samples to ensure quality and specifications meet client requirements. These tests ensure that the ball will be efficient in the mills. The product is cleared for shipping, then it is packed in bags and loaded on a truck to be transported to its destination.
Here at Camasteel we have Forge steel Balls for sale.
Contact Us:
Email: [email protected]
Website: www.camasteel.com
LinkedIn https://www.linkedin.com/company/camasteel
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Twitter: https://twitter.com/Camasteel2
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No complaints review by Mwanawasa P. on 6/15/2022Steel Balls were fine and arrived on time. Thanks!
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Forged Steel Grinding Balls review by Tyler on 6/10/2021
I STRONGLY recommend forged steel grinding balls to EVERYONE interested in running a successful business!
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