10
2012
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07
Comparison between Cast Steel Balls and Forged Steel Balls
Author:
Compared with cast grinding balls, hot-rolled steel balls represent a completely new rolling process technology—a breakthrough in the manufacturing of ball-mill grinding media—and are gradually replacing cast balls.
Comparison between cast balls and forged steel balls:
The main drawbacks of the casting ball production process are:
1. Cast balls are essentially made of pig iron; after adding a large amount of chromium (13–28%), they meet the requirements for grinding balls.
2. Cast balls have a loose microstructure and coarse grains, resulting in relatively poor wear resistance and low impact toughness (typically 3–7 J/cm³), with a breakage rate exceeding 3%.
3. High energy consumption, significant pollution, high labor intensity for workers, and low labor productivity
4. High raw material and labor costs, especially for small balls with a diameter of 50 mm or less, which incur even higher costs.
Compared with cast grinding balls, hot-rolled steel balls represent a completely new rolling process technology and constitute a significant technological breakthrough in the manufacturing of ball-mill grinding media. They are gradually replacing cast balls and exhibit the following characteristics:
1. Hot-rolled steel balls possess all the advantages of steel and, after heat treatment, become high-quality grinding media for ball mills.
2. High production efficiency and large output; ball-rolling production is highly mechanized and automated, with no manual operations and minimal labor requirements.
3. Stable quality, high hardness, excellent hardenability, dense microstructure, fine grain size, and superior wear resistance—wear loss is only half that of cast balls; impact toughness reaches 12–35 J/cm², and the breakage rate is less than 0.1%.
4. Low energy consumption, zero pollution, low labor intensity, and lower production costs
In the long run, cast balls will inevitably be replaced by forged balls.
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