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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 1100ºC(±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.
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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