Grinding media manufacturing process

The grinding media is widely used in metallurgical mines, cement building materials, thermal power generation, flue gas desulfurization, and other industries ball mill. But what is the manufacturing process of the grinding media? We will explain here clearly. (Here we mainly talked about the casting grinding media.)

Producing the qualified grinding media, there are four essential steps. First melting, second molding, third separating, and the last heat treatment. 

  1. Melting. The furnace the factories most used are the medium frequency induction furnace, fast and stable. It’s easy to add the ferrochrome and the other elements inside. The raw material we required is the iron scrap. Grey iron is not good enough for producing grinding balls. Because of the carbon contents too much. After melting, we have to clean up the slags and pouring the pure liquid iron into the metal mold. To ensure the right chemical composition, after melting and before pouring, the operator should get some to do the analysis test. Its each chemical composition is right. Then we can do the next step.
  2. Molding. There is different method to form the balls. For example, using the manual metal mold to produce or sand mold; or we can use the automatic manufacturing machine to produce, like automatic sand-lined metal mold grinding balls production line; or Disa production line or any other green sand molding line. With the help of the pouring device or pouring ladle, pouring the liquid into the prepared mold. For manufacturing grinding media, we required one-time pouring. If the last pour is unfilled, then  we regard the formed media as the discarded product.
  3. Separating. As we all know, if we want to ensure the no holes inside and get better quality of the inner structure of the media, there will be a pouring gate that is used for feeding enough molten iron to the balls. So after the grinding media formed, they are connected with the runners and gates. Have to separate. There are also two methods, one is anauto separating machine which can process grinding balls over 40mm, and the hourly productivity can up to 3-5tons. This type is suitable for medium and large grinding balls factories to achieve high efficiency. Another manual method is using a separate machine; the principle is that the friction between the balls to make separation. But for some big size of the balls, like dia130mm, the operator usually uses a grinder to cut. So after separating, then to go to the last step.
  4. Heat treatment. Heat treatment is a vital process for a good ball. This process will change the ball’s characteristics, increase the hardness, reduce the inner stress. To achieve the formed grinding balls have good impact value and low wear rate. This process includes quenching and tempering. And the heat treatment machinealso has several types with different daily processing ability. 

After above 4 steps, the excellent balls produced, and can package and put into usage. 

grinding media manufacturing process

Hexin is a years and experienced company which have helped many clients home and abroad to updated or establish a grinding balls foundry. Hexin company supplies the whole set of the grinding balls equipment and supports the manufacturing technology. Weclomed everyone to come and cooperate with us!

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