By: Ashley August 26, 2019 Last Updated :September 12, 2019
There is no doubt steel ball mill balls are now the most wear-resistant material consumables among the world crushing industry. The data shows that about 2 million tons of hardened steel ball mill balls deigned with different materials have been consumed only in the industry of beneficiation.
The shape of ball mill balls is round. After the physical effect, the round ball mill balls can be shaped neat or irregular round bar, square bar. After heating at a certain set temperature, they will rely on the die for free forging. Fote company has improved modern technology again in recent years, complete achieving the goals of rolling mill production, roll forging production. I believe that generations of steel ball people will continue to fight for it. Only walking into the world of steel balls can you feel they are not the cold iron block but the beautiful embodiment. You can think about this: a round steel ball run in the ball mill. It contributes to the world by smashing large ore, closely connecting with everything in life. Just like our human Tiangong No.1 and No.2, are exploring and running.
The ball mill ball plays a very important role in grinding. The ball mill balls can produce huge impact on the mineral material, collision, extrusion, etc., and the mineral material is gradually ground to the qualified particle size. When the ball mill ball is selected, the size is required to be accurate. The hardness is high, so it is not easy to be deformed and broken. The quality of the ball mill ball directly affects the grinding effect. It is very important to choose the right ball mill balls suppliers.
>Ball mill balls grinding media
Whatever the steel ball mills manufacture or the mining project that are using the ball mill balls. There is a common question that during the operation of the ball mill, the steel ball will break, why? A fundamental problem is an internal stress.
We can simpley say that, the internal stress is a measure of degree of deformation, strength, impact toughness and other physical quantities associated with the failure of an object. Generally speaking, internal stress is the internal pressure.
Forgings are processed by hammers, just like kneading the dough. If the forged steel ball is immediately taken to the lathe for processing, the dimensional accuracy fully meets drawing requirements. But after a short time, the dimensional accuracy is not qualified again. However, what’s the problem? The internal stress of the forging has not been eliminated, causing the deformation of the workpiece. The solution is to throw the workpiece aside, and wait for its internal stress to be eliminated, the internal structure is even, loose and consistent. Then, the size of the workpiece thus processed will not change.
Working principle of steel balls
The client is a well-known minerals company in the Middle East and has many minerals of its own. FTM Machinery has a long history of manufacturing. Our ball mill balls have exported to 74 countries such as America, Germany, Japanese, British, and India. Before choosing FTM Machinery, the customer has conducted market research and several rounds of negotiation and inspection. They believe that Henan Fote Heavy Machinery Co., Ltd. is a professional mining equipment manufacturer with strong manufacturing strength and production history of more than 25 years.
Most customers consider the quality and capacity of the ball steel balls, but Fote mining machinery can offer you the whole process plan including equipment selection, site planning, etc. This customer has ordered three steel balls production lines（30mm，40mm,60mm).
Ball mill balls
Steel balls are the main media for ball grinding mills. The consumption of steel balls is very large, about 10 times more than the ball mill liner. To make up for the loss of steel balls and ensure ball load particle size in the ball mill is unchanged, you should add steel balls according to a certain ratio.
The consumption of ball mill balls is mainly due to mechanical wear and corrosion wear. They are the “physical-mechanical” and “physical-chemical” irreversible processes that occur on solid surfaces. Under the premise of ensuring the quality of ball mill, how to effectively reduce the energy consumption of the ball mill ball?
The granularity of material is one of the factors that affect the consumption of ball mill. Generally, the grindability of feed particle size is small, and the ore is easy to grind, the wear of the ball mill ball is smaller, and the energy consumption is also small.
As for the hard rock or stone, you can consider adding certain chemicals in the grinding process to improve the grinding effect and increase the grinding efficiency when the economic and site conditions permit. Or heating the ore to change the mechanical properties of the whole ore and reduce mineral hardness.
The ball mill has a large particle size, and the ball mill has more work on the material. To achieve the specified grinding fineness, the workload of the ball mill is bound to increase, and the energy consumption of the steel ball will increase. You can reduce the size of the feeder of grinding mill to reduce the consumption of the ball mill.
When the rotational speed of the ball mill reaches a certain level, the filling rate is large, and the number of hits of the steel ball on the material is increased.if the filling rate is too high, the operation state of ball mill will change, and this can reduce the impact on large particle materials. However, if the filling rate is too low, the effect of grinding is not obvious.
At present, the filling rate of steel balls in the grinding operation of the beneficiation is generally 45%~50%. If it is not a reasonable filling rate according to the actual conditions of each factory, it is necessary to determine the reasonable amount of ball loading through the beneficiation test.
When the rotational speed of the ball mill reaches a certain level, the filling rate is large, and the number of hits of the steel ball on the material is increased, the grinding area is large, and the wear is fast. If the filling rate is too high, it will change the motion state of ball mill steel balls to reduce the impact on large particle materials. If it is not a reasonable filling rate according to the actual conditions of each factory, it is necessary to determine the reasonable amount of ball loading through beneficiation test.
Because steel balls in the ball mill are in point contact with the material, if the diameter of steel ball is too large, the crushing force is also large, the wear is too fast, and the material is easily broken along the penetrating force direction, which affects the grinding efficiency. Besides, under the same case, if the ball diameter is too large, the ball volume will be small, the breaking probability will be low, the over-grinding phenomenon will be intensified, and the product granularity will be uneven. If the steel ball is too small, the crushing force on the ore is small, and the grinding efficiency is low. Therefore, reasonable steel ball size and ratio not only reduces the steel consumption of ball mill but also effectively improves the grinding efficiency.
Different sizes of ball mill balls
The concentration of grinding concentration will affect the specific gravity of the slurry, the degree of adhesion of the material around the steel ball and the fluidity of slurry. If the grinding concentration is high, the adhesion of the material around the steel ball is good, the impact and grinding effect of steel ball on the material is also large, and the steel ball wears faster. In the production, the concentration of grinding can be controlled by controlling the amount of ore, or the amount of water supplied or adjusting the classification.
Under the premise of reasonable ball mill steel ball ratio, if the rotating speed is of ball mill increases, the steel ball in the cylinder will fall into a parabolic state. When the transfer rate is increased to a certain value, the useful power reaches the maximum value. At this time, the grinding effect is the best, and the ball mill ball wear is also the most reasonable. The theoretical critical rate of ball mill is generally 78 to 84%. Due to the nature of the material and other factors, the ball mill speed should be determined according to the actual situation.
Many factors can affect ball mill steel ball energy consumption during grinding. Furthermore, most factors are difficult to quantitatively analyze, and can only be qualitatively analyzed and judged. To reduce the power consumption of the ball mill ball under the premise of ensuring reasonable quality indicators, we must consider from multiple links and control every link to achieve the final technical and economic indicators and good product quality indicators.
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