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Steel Ball Lines

Development trend of the steel ball skew rolling mills:

Steel ball hot rolling is a brand-new technology of skew rolling, and it is a technological breakthrough in grinding ball manufacturing, and it is gradually replacing cast steel balls. With the rapid development of China's national economy, mine, cement, thermal power, refractory material, steel, and phosphate fertilizers industries, and the demand for grinding steel balls is increasing. At present, the annual consumption of grinding steel balls in China has exceeded 5 million tons, and there is an increasing trend year by year. In addition, the export market for grinding steel balls in China is prosperous, mainly exported to Australia, South Africa, Ghana, Brazil, Russia, Mongolia, Indonesia, the United States, and Chile. Algeria and other countries.

In modern industry, the manufacture of steel balls requires very accurate dimensions and surface quality. These steel balls are mainly used in mines, power plants, cement plants, steel mills, silica sand plants, and coal chemical industries. One of the methods for making these steel balls is through skew rolling. Skew rolling is the forming process by the use of two specially designed continuously-rotary vertical rollers. The steel bar is fed to the rollers, and through the squeezing and cutting of the rollers, ultra-final round steel balls are formed. It can be said that the rolling process of each steel ball is independent. The skew-rolling process, similar to roll forging, this manufacturing process allows the steel ball to contain the dual qualities of steel ball forging and steel ball rolling.

Hot rolled steel balls: The quality of grinding media (balls, baseballs) plays a decisive role in the operating costs of the dressing plant.

1. The steel consumption (grinding medium, lining) in normal dressing plant, power electricity accounts for 50 to 70% of the operating costs;

2. High-quality steel balls can effectively increase the production efficiency (output) of the grinding machine, thereby reducing the production and operating costs.

3. Some well-known mining companies such as Rio Tinto, BHP Billiton, Minmetals, CITIC Pacific SINO Iron Mine, Shougang Peru Iron Mine, Chilean Copper, Vale, McMurray Copper Gold, Baruch Gold, etc., have adopted rolled steel balls. They are outstanding leaders in resource conservation, carbon reduction, and green mines.

At present, the product specifications of the skew rolled steel ball range from φ20 to φ150. The wear-resisting steel balls for gold mines, silver mines, copper mines and iron mines are widely used and promoted in actual mines, saving great purchase costs for customers, greatly increasing the grinding production, and achieving a remarkable economy benefit.

Steel ball rolling mill is a special equipment for producing grinding steel balls, bearing ball blanks and other metal ball parts (nominal diameter φ20-φ150mm) by adopting the spiral roller pass rolling forming process, and can also be used for producing other rotary parts or blanks. The steel ball rolling machine adopts a semi-closed frame, easy to change the rollers, the adjustment function of the rolling mill is complete, the rigidity of the stand is good, and the precision of the rolled product is high. The whole steel ball rolling machine consists of main motor, reducer, compound device, universal coupling , work host and other parts.

 

Steel ball skew rolling mill production process:

The steel ball skew rolling forming process is a new technology for forming rotary parts or parts blanks. It can be used to produce grinding mill steel balls, bearing rollers, automotive parts and circuit hardware and other products, with the advantages of greatly increasing labor productivity, saving metal, improving product quality, reducing product cost, and improving working conditions.

Hot rolled steel ball is a new type of rolling technology. It is a process breakthrough of grinding steel ball manufacturing technology, and it has been gradually replacing the casted ball. The hot rolled steel ball has the following characteristics:

1) Hot rolled steel ball has all the advantages of steel, and been used as high quality grinding balls after heat treatment.

2) High efficiency, large capacity, mechanization of steel ball rolling production, high degree of automation, no need for manual production, and less and less interference of worker factors.

3) Stable quality, high hardness, good hardenability, compact microstructure, small crystal grain, homogeneous steel ball with no deformation, no breaking circle, good wear resistance, impact toughness is as high as 12-35 j/cm2, and the crushing rate is less than 1%.

4) Low energy consumption, no pollution, low labor intensity, low production cost, good formability, small geometric tolerance, and stable quality.

5) The wear rate is low and the service life is long. It is an existing cast iron ball, and the price is reasonable.

6) The steel ball hardness is up to 60 ~ 67 HRC, internal and external hardness is balanced.

7) Impact toughness up to 12~35j/cm3.

8) Large proportion (7.8〜7.85 J / cm3).

9) The surface quality of the steel ball is good, and the hardness inside and outside is balanced (hardness difference <5HRC);

10) Low crushing rate, long service life, high ball density, strong impact toughness;

The wear-resistant steel ball rolling mill production line adopts fully automatic production line operations, without manual intervention, automatic production, and it can guarantee the stability of steel ball quality to the utmost. The production line is environmentally friendly and energy-efficient. The produced steel balls have precise and round geometry, high hardness and good mechanical properties, and have high impact toughness and strong crushing resistance.

Steel ball rolling is a new type of rolling technology. There are many advantages. Then what is the steel ball hot rolling process?

1. After the round bar has been inspected, it is cut to a fixed length for hot rolling according to the required length.

2. The steel bar is heated to a suitable temperature in a continuous furnace before rolling.

3. The red billet is fed into the skew rolling mill, and special spiral groove rollers are used to rotate the billet between the furnace and the skew rolling mill, and the billet is then continuously rolled into steel balls. Each steel ball skew rolling mill can roll 60-360 balls per minute.

4. The steel balls run into the factory specifically designed in-line quenching - tempering heat treatment, the heat treatment equipment enables the steel balls to get a high and uniform hardness, and then the steel balls immediately turn into hot red state.

5. The inspected qualified product is delivered to the finished product warehouse, and packaged for the customers.

The steel ball production methods generally include forging steel balls, grinding steel balls and casting steel balls. According to the processing material, the steel ball is divided into bearing steel ball, stainless steel ball, carbon steel ball, copper bearing steel ball, alloy steel ball and so on. Among them, the bearing steel ball is an important basic component of the industry. The alloy steel ball is a ball-shaped ferro-alloy wear-resistant body which is mainly added with carbon, chromium, manganese, molybdenum, etc., and is produced through forging, spinning, rolling and casting, etc. It is used as crushing steel balls in mining industry and cement industry.

The advantages of rolled steel balls:

For casting steel balls, forging steel balls, and rolling steel balls, due to different production processes, there are many unconquerable disadvantages in casting steel balls and forging steel balls. Rolled steel balls have obvious advantages compared with cast steel balls and forged steel balls, especially in terms of quality.

Hot rolled steel ball quality advantages:

• Good shape, small geometric tolerance, stable quality.

• Low wear rate and long service life.

•Steel ball hardness up to 60 ~ 67HRC, balanced internal and external hardness, hardness difference <5HRC.

• Impact toughness up to 12~35J/cm3.

• Large proportion (usually greater than 7.85J/cm3).

The direction of development of grinding steel ball industry, according to the Standing Information Center, there are hundreds of big or small steel ball manufacturers currently excluding the exporters, and the annual domestic consumption of grinding balls (forged steel balls, cast steel balls) is over 5 million tons.

As a brand-new rolling process technology, hot rolling ball grinding ball is a technological breakthrough in grinding ball manufacturing industry and is gradually replacing cast grinding steel balls and forged steel balls. In addition to product quality advantages, hot-rolled balls have the following characteristics: 1. Hot-rolled balls have all the advantages of steel, and they become high-quality ball balls after heat treatment. 2. there is no need for manual operation, and less interference from human factors;

Due to the advancement and superiority of hot rolling balls in the production process, product quality, practical use, production costs, energy consumption, environmental protection, etc., together with the current status of grinding steel ball in China, the rolled grinding steel ball will replace the cast steel balls and forged steel balls, has become the development direction of the grinding steel ball industry.

 

Steel Ball Hot Rolling Mill:

Steel ball hot rolling is a new skew rolling process technology and it is a technological breakthrough in grinding steel ball rolling mill manufacturing, and it has been gradually replacing the casted steel balls.

Main Process:Round bar steel→ Feeding device→ Induction heating furnace ( 900℃ to 1100℃ )→ Rolled into formed steel ball→ Automatic steel ball screening and dividing equipment→ Annealing device→ On-line tempering → Natural cooling→ Secondary tempering (optional)→ Packaging

Steel ball hot rolling process description:

<1> Billet stacking: Stock the steel ball billets in the stockyard;

<2>Feeding: The billets are normally lifted by the overhead crane to the feeding rack, and pulled out onto the conveyor roller by the automatic turn-over mechanism.

<3> Induction heating: The billets are heated by the medium frequency induction furnace , fully automatic PLC controlled;

<4>Rolling: The speed of main rolling motor can be adjusted in variable frequency to meet the production requirements of steel balls of different specifications and match with the induction heating furnace;

<5> Conveyor delivery: The steel ball is conveyed to the screening section; the transmission motor adopts variable frequency speed regulation, which can help adjust the pre-cooling temperature of the steel ball;

<6> Screening: The imperfect steel balls are screened out by the screening machine and run into the waste container;

<7>Uniform temperature slow-cooling: Slow cooling chain motor adopts variable frequency speed regulation, so that the high temperature steel ball can be cooled and can be cooled to the quenching temperature by adjustment, meanwhile the steel ball temperature gets uniformity;

<8> Steel ball dividing: The after-screened ball is divided into two by dividing machine , and run into the quenching tank;

<9> Quenching: The steel ball is quenched by two parallel installed quenching machines, and the quenched spiral-groove motor adopts variable frequency speed regulation, and adjusts the outlet water temperature after the ball is quenched;

<10> Collection: The steel balls are collected by the collection box;

<11>Off-line tempering: Tempering treatment is processed by the off-line resistance furnace;

<12> Cooling: Cool the steel balls to normal temperature;

<13> Weighing and packaging storage: bagging, storage;

 

Hot rolled steel ball: Φ15、φ20、Φ25、φ30、Φ40、φ50、Φ60、φ70、Φ80、φ90、φ100、Φ110、φ120、Φ125、Φ130、φ140、Φ150

Hot rolling steel sections: 14×16、16×20、18×22、20×24、25×40、40×60、45×70、50×80

Application fields20mm-150mm rolled steel balls can be used in mining plant, cement plant, thermal power plant, refractory plant and other steel industries.

 

Skew Steel Ball Rolling Mill:

Main Process: Round bar Steel→ Feeding device→ Induction heating furnace ( 900℃ to 1100℃ )→ Rolled into formed steel ball→ Automatic steel ball screening and dividing equipment→ Annealing device→ On-line tempering → Natural cooling→ Secondary tempering (optional)→ Parking

Application fields: 20mm-150mm Rolled Steel Balls are used in mining plant, cement plant, thermal power plant, refractory plant and other steel field.

Skew Rolling Mill Line technical advantages:

Full automatic design process by professional design skew rolling mill for steel ball rolling mill plant.

Low consumption running in the steel ball rolling mill plant for producing the steel ball.

Accuracy form and diameter of steel ball production.

Higher efficiency productivity of steel ball rolling mill line.

Fuel consumption by Gas or electric for steel ball rolling mill line.

  

Product specification

 Raw Material  Dia.

Ball Dia.

Ball Weight    /PCS

Ball Dia.  Tolerance

Ball Non-Roundness

Line Speed

Capacity

(mm)

(mm)

(g)

 (mm)

(mm)

(pcs/min)

(kg/h)

20

20.96

37

0

≤1.5

180

400

25

26.2

72

-0.5

≤1.5

110

500

30

31.4

125

-0.5

≤2.0

100

750

40

41.8

300

-0.5

≤2.5

55

990

50

52

578

-1

≤3

95*2

6500

60

62.4

999

-1

≤3

108

6400

65

67.6

127

-2

≤4

90

6800

70

72.8

1586

-2

≤4

75

7100

75

78

1951

-2

≤4

65

7600

80

83.2

2367

-2

≤4

80

11300

85

88.4

2839

-3

≤4.5

70

11900

90

93.6

3371

-3

≤4.5

65

13100

95

98.8

3964

-3

≤4.5

60

14200

100

104

4623

-3

≤4.5

50

13800

110

114.4

6154

-4

≤5

40

14700

120

124.4

7989

-4

≤5

30

14300