Manufacturing Process of Forged Balls:
Steel bars material
The forged steel balls are produced from high quality hot rolled steel bars.We tailor the chemicals according to the balls diameter and customer request to achieve optimum performance.Strategic cooperation with local steel factory assures the supply of material in time.
Electric furnace heating
The material is heated by electric furnace which ensures accurate output temperature of each piece.The temperature is one of the most important factors affect the final grinding ball hardness in the heat treatment.
Forging process
The balls are forged by air hammer to 25-130mm.Strictly control and many years experience enables to achieve very high surface quality.The annual output is over 20000 tons.Production standard:YB/T091-2005.
Heat treatment
The balls are heat treated to required hardness by water quenching and tempering.The heat treatment know how secures the achievement of accurate hardness range required by the customer.The temperature is one of the most important factors affect the final balls hardness.
Steel ball inspection
Specified number of balls is withdrawn from each production lot during the production process.Each of the withdrawn balls is then subject to surface quality,hardness and impact value test etc.The test report will be sent to customer with each order.
Steel ball packing
The balls are packed as required by the customers.We offer packing in steel drums or flexible container bags rolled by bubble sheet.The services provided by the company include the arrangement of grinding ball transport by truck and load into containers.
Process Features of Forged Balls:
Material stability
The raw material of forged balls are round steel,ordered from national large-scale steel mills.We can also provide special processing as per special requirement of different grinding balls materials.
Heating of raw material
Adopting energy-efficient induction Bar furnace to heat the raw material.It has two advantages:
A:Ensure uniform temperature of the entire raw material,and then the uniform temperature can ensure even hardness during heat treatment process.
B:Lower raw material consumption.
Forged Forming
The raw materials are forged to a certain deformation by forged equipment,increase compression ratio,so that to dense the structure of wear-resistant ball and improve the toughness and hardness.
Heat treatment
We’re using independently-developed water quenching heat treatment production line and scientific heat treatment process.Our forging grinding balls have the specialities of higher hardness(from surface to the core),high toughness and low breakage.They can even maintain the stability under various poor working conditions.
Technical Parameters of Forged Balls
Type and Chemical Composition of Forged Balls
Name | Material | C | Mn | Si | Cr | S | p | Mo&Ni |
YT-1 | 45# | 0.42-0.50 | 0.5-1.0 | 0.17-0.37 | ≤0.25 | ≤0.035 | ≤0.035 | Trace |
YT-2 | 60Mn | 0.57-0.65 | 0.7-1.0 | 0.17-0.37 | ≤0.25 | ≤0.035 | ≤0.035 | Trace |
YT-3 | 65Mn | 0.60-0.70 | 0.9-1.2 | 0.17-0.37 | ≤0.25 | ≤0.035 | ≤0.035 | Trace |
YT-4 | B2 | 0.75-0.85 | 0.8-0.9 | 0.17-0.37 | 0.5-0.6 | ≤0.035 | ≤0.035 | Trace |
YT-5 | 75SiMn | 0.7-0.90 | 0.7-1.2 | 0.4-0.8 | ≤0.25 | ≤0.03 | ≤0.03 | Trace |
YT-6 | 40MnCr | 0.45-0.50 | 0.7-1.2 | 0.17-0.37 | 0.9-1.1 | ≤0.03 | ≤0.03 | Trace |
Physical Property of Forged Balls
Name | Material | Impact Test (AK.J/CM2) | Endurance test(times) | Hardness(HRC) | Breakage Rate |
Dia20mm-90mm | Dia100mm-150mm |
Surface | Core | Surface | Core |
YT-1 | 45# | ≥12 | ≥10000 | ≥55 | ≥35 | ≥50 | ≥30 | <1% |
YT-2 | 60Mn | ≥13 | ≥10000 | ≥60 | ≥45 | ≥55 | ≥40 | <1% |
YT-3 | 65Mn | ≥15 | ≥12000 | ≥60 | ≥45 | ≥56 | ≥40 | <1% |
YT-4 | B2 | ≥17 | ≥12000 | ≥60 | ≥55 | ≥58 | ≥50 | <1% |
YT-5 | 75SiMn | ≥16 | ≥12000 | ≥60 | ≥50 | ≥60 | ≥48 | <1% |
YT-6 | 40MnCr | ≥16 | ≥12000 | ≥60 | ≥50 | ≥60 | ≥48 | <1% |
Weight and Microstructure of Forged Balls
Nominal diameter(mm) | Diametrical Tolerance(mm) | Approx weight per ball(kgs) | Average number per MT | Microstructure |
25 | +1.5,-0.5 | 0.064 | 15625 | M+B+C {C}(M-{C}Martensite {C}B-{C}Bainite C-Carbide) |
30 | +1.5,-0.5 | 0.11 | 9090 |
40 | +2.0,-1.0 | 0.26 | 3846 |
50 | +2.0,-1.0 | 0.51 | 1961 |
60 | +3.0,-2.0 | 0.89 | 1124 |
70 | +3.0,-2.0 | 1.4 | 714 |
80 | +3.0,-2.0 | 2.1 | 476 |
90 | +3.0,-2.0 | 3 | 333 |
100 | +4.0,-3.0 | 4.1 | 244 |
110 | +4.0,-3.0 | 5.47 | 283 |
120 | +4.0,-3.0 | 7.1 | 141 |
130 | +4.0,-3.0 | 9.02 | 111 |
Our value propositionSteady qualityWe value much of our commitment to you.The customer will get quality product as they want.Supply assuranceCertainty of supply is critical for the continuity of mill operations.We will follow customers request and deliver the goods in time.Strategic cooperation with local steel factory assures the supply of material in time.Reasonable priceReasonable price is the basis of long term cooperation. Quality ControlOur products follows strictly with standard production process,the technicans supervise the process to record and control the key quality point.The quality of our products can meet the request from different countries and areas, and has got high reputation.Package and TransportationIn order to serve customers with timely delivery, we load the products to steel drums or containers bags timely after check. And then transport the goods by truck, vessel or air, to assure the goods arrive at customers’ dominated place with safety.
