An energy-saving grinding ball and its preparation method

Abstract

The application discloses an energy-saving grinding ball and a preparation method thereof. The mass percentages of the respective components are as follows: ferrochrome: 60-65 parts, zirconia nanoparticles 1-2 parts, zirconia microparticles 3-6 parts, calcium tungstate 0.3-1 part, high-carbon steel 3-5 parts, ferrosilicon 5-6 parts, aluminum 2-3 parts, ferromanganese 2-4 parts, magnet 3-4 parts, tungsten-molybdenum alloy 2-3 parts, silicon carbide fiber 1-2 parts, copper 1-2 parts. The grinding balls prepared by the application show obvious advantages in terms of hardness, wear resistance and grinding efficiency. These technical advantages enable the grinding balls to have a broader application prospect in the industrial processing field and to provide a more efficient and more economical grinding solution.

Description

Technical Field

[0001] This application relates to the field of surface treatment, and particularly to an energy-saving grinding ball and its preparation method. The energy-saving grinding ball has higher hardness and higher grinding efficiency. Background Art

[0002] In industrial processing and material handling processes, the use of grinding balls is widely applied in fields such as grinding, polishing, and surface treatment. However, traditional grinding balls pose some challenges in terms of grinding efficiency and energy consumption.

[0003] Traditional grinding balls have some deficiencies in industrial processing and material handling, which are mainly caused by their material and design characteristics. Specifically, the material and structural design of traditional grinding balls limit their grinding efficiency. Their surface friction coefficient is relatively high, resulting in more heat and energy loss. At the same time, the wear rate of the grinding balls is relatively fast, reducing the grinding efficiency. In addition, the hardness and structure of traditional grinding ball materials make them prone to wear and deformation, resulting in a short service life of the grinding balls, requiring frequent replacement, increasing costs and maintenance difficulties. Moreover, due to the low grinding efficiency and frequent replacement of grinding balls, traditional grinding balls consume a large amount of energy in the industrial processing process, increasing energy costs and environmental burdens. Finally, in order to achieve higher hardness, some traditional grinding balls use materials containing harmful substances, and their production and treatment processes may cause environmental pollution and waste of resources. To overcome these problems and improve the performance of grinding balls, it is important and necessary to develop new energy-saving grinding balls. Summary of the Invention

[0004] The purpose of this application aims to at least overcome one deficiency of the existing technology, and provides an energy-saving grinding ball with high hardness and high grinding efficiency and its preparation method.

[0005] To achieve the above purpose, in the first aspect, this application discloses an energy-saving grinding ball, and the mass percentages of each component are as follows:

[0006] Ferrochrome: 60 - 65 parts, zirconia nanoparticles 1 - 2 parts, zirconia microparticles 3 - 6 parts, calcium tungstate 0.3 - 1 part, high-carbon steel 3 - 5 parts, ferrosilicon 5 - 6 parts, aluminum 2 - 3 parts, ferromanganese 2 - 4 parts, magnet 3 - 4 parts, tungsten-molybdenum alloy 2 - 3 parts, silicon carbide fiber 1 - 2 parts, copper 1 - 2 parts.

[0007] As a preference, the chromium content of ferrochrome is 60% - 65%, and the iron content is 35% - 40%.

[0008] As a preference, the zirconia nanoparticles are spherical or quasi-spherical zirconia particles with a diameter of 80 - 90 nanometers.

[0009] As a preference, the zirconia microparticles are irregular zirconia particles with a diameter of 1 - 3 micrometers.

[0010] As a preference, calcium tungstate is selected in the form of 100-mesh powder.

[0011] As a preference, the magnet is selected in the form of powder.

[0012] As a preference, the tungsten-molybdenum alloy is selected as spherical tungsten-molybdenum alloy powder.

[0013] As a preference, the silicon carbide fiber is selected with a length of 1-3 cm and a diameter of 10-20 microns.

[0014] To achieve the object of the present application, in a second aspect, the present application discloses a preparation method of energy-saving grinding balls based on the above mass ratio, which includes the following steps:

[0015] Step 1, prepare materials according to the ratio.

[0016] Step 2, pre-treat zirconia nanoparticles, zirconia microparticles, calcium tungstate, high-carbon steel, ferrosilicon, aluminum, ferromanganese, magnet, tungsten-molybdenum alloy, silicon carbide fiber and copper by drying to remove impurities and moisture.

[0017] Step 3: Mix zirconia nanoparticles, zirconia microparticles, calcium tungstate, tungsten-molybdenum alloy, and silicon carbide fiber using a blender to form a mixture for standby. The mixing time is not less than 30 minutes and the rotation speed is not less than 300 revolutions per minute.

[0018] Step 4, heat ferrochrome to 1500-1600 °C to make it in a molten state, then sequentially add high-carbon steel, ferrosilicon, aluminum and ferromanganese and heat to 1700-1800 °C. The raw materials are fully melted to form a uniform molten liquid, and then add the mixture formed in Step 3 and the magnet and stir to make the molten liquid and the mixture evenly mixed.

[0019] Step 5, lower the temperature of the molten liquid to 1200 °C and pour it into a casting ladle for casting.

[0020] Step 6, start quenching when the temperature of the iron balls obtained by casting in Step 4 drops to 800-900 °C. The quenching medium is quenching oil, and its temperature should be controlled below 80 °C to ensure rapid cooling and good quenching effect. The iron balls stay in the quenching oil for enough time to ensure complete quenching. The quenched iron balls need to be tempered. The tempering temperature is 320 °C and the tempering method is isothermal tempering, that is, heat the iron balls to the tempering temperature and keep them for a period of time to make them reach the required structure and properties.

[0021] Step 7, naturally cool the iron balls obtained in Step 6 to room temperature to obtain grinding balls.

[0022] Additional aspects and other advantages of the present disclosure will be given in part in the following description, become apparent in part from the following description, or be learned through the practice of the embodiments of the present application. Description of the Drawings

[0023] Figure 1 is a test data table in the implementation of the present application. Detailed Description of the Embodiments

[0024] For the convenience of understanding the present application, the following is a brief analysis of each component first:

[0025] Ferrochrome: As the main component of the grinding ball, chromium and iron can significantly improve the hardness and wear resistance of the grinding ball. The chromium element can improve the wear resistance of the material, while iron is the basic element of the grinding ball, providing the basic hardness for the grinding ball.

[0026] Zirconia nanoparticles and zirconia microparticles: Zirconia is a very hard material with good wear resistance. Here, we improve the overall performance of the grinding ball by mixing nanoparticles and microparticles because the two particle sizes can complement each other, improving the uniformity and strength of the grinding ball.

[0027] Calcium tungstate: Calcium tungstate is also a material with high hardness, which can improve the hardness and wear resistance of the grinding ball.

[0028] High-carbon steel: High-carbon steel is a steel with high hardness. It can not only improve the hardness of the grinding ball but also has good impact resistance.

[0029] Ferrosilicon: Ferrosilicon is an alloy with high hardness, which can further improve the hardness of the grinding ball.

[0030] Aluminum: Aluminum is a light metal. It can improve the oxidation resistance of the grinding ball, preventing the performance degradation of the grinding ball in high-temperature or oxidation environments. At the same time, aluminum also has a certain plasticity, which helps the grinding ball resist impact force.

[0031] Ferromanganese: Ferromanganese is a wear-resistant material, which can improve the hardness and wear resistance of the grinding ball.

[0032] Magnet: The magnet can improve the hardness and magnetism of the grinding ball.

[0033] Tungsten-molybdenum alloy: Tungsten-molybdenum alloy is a material with extremely high hardness, which can significantly improve the hardness and wear resistance of the grinding ball.

[0034] Silicon carbide fiber: Silicon carbide fiber is a high-strength material, which can improve the impact resistance and wear resistance of the grinding ball.

[0035] Copper: Copper is a good heat-conducting material, which can assist in improving the wear resistance and impact resistance of grinding balls. Copper helps to disperse the heat generated during the use of grinding balls, preventing temperature concentration and thus reducing the impact on the performance of grinding balls. In addition, the plasticity of copper also helps grinding balls to resist impact force.

[0036] Through the above analysis, it can be seen that this application comprehensively improves the properties of grinding balls such as hardness, wear resistance, impact resistance, oxidation resistance and magnetism by means of multi-element alloy and multi-scale particles. Such a design enables the grinding balls to have good performance under different working conditions, significantly improving their practicality. At the same time, the disclosure of this grinding ball material formula also provides a new thinking and reference for technicians in related fields, which is conducive to promoting the development and progress of grinding ball material technology.

[0037] The embodiments disclosed in this application will be described below. However, it should be understood that this disclosure can be presented in many different ways and is not limited to the embodiments described below; in fact, the embodiments described below are intended to make this disclosure more complete and fully explain the protection scope of this disclosure to those skilled in the art. It should also be understood that the embodiments disclosed herein can be combined in various ways to provide more additional embodiments.

[0038] Example 1;

[0039] In this embodiment, 60 parts of ferrochrome, 1 part of zirconia nanoparticles, 3 parts of zirconia microparticles, 0.3 part of calcium tungstate, 3 parts of high-carbon steel, 5 parts of ferrosilicon, 2 parts of aluminum, 2 parts of ferromanganese, 3 parts of magnet, 2 parts of tungsten-molybdenum alloy, 1 part of silicon carbide fiber and 1 part of copper are prepared. In order to remove impurities and moisture, the zirconia nanoparticles, zirconia microparticles, calcium tungstate, high-carbon steel, ferrosilicon, aluminum, ferromanganese, magnet, tungsten-molybdenum alloy, silicon carbide fiber and copper are dried. A mixer is used to mix the zirconia nanoparticles, zirconia microparticles, calcium tungstate, tungsten-molybdenum alloy and silicon carbide fiber to form a mixture for standby. The mixing time is not less than 30 minutes and the rotation speed is not less than 300 revolutions per minute. The ferrochrome is heated to 1500 - 1600 degrees Celsius to make it molten. Then, high-carbon steel, ferrosilicon, aluminum and ferromanganese are added in sequence and heated to 1700 - 1800 degrees Celsius. After the raw materials are fully melted and form a uniform molten liquid, the mixture and magnet mixed in step 3 are added and stirred to make the molten liquid and the mixture evenly mixed. The temperature of the molten liquid is reduced to 1200 degrees Celsius, and then it is poured into a casting ladle for casting and forming.

[0040] In this embodiment, when the temperature of the cast iron ball drops to 800 - 900 degrees Celsius, quenching begins. The quenching medium is quenching oil, and its temperature should be controlled below 80 degrees Celsius to ensure rapid cooling and good quenching effect. The iron ball stays in the quenching oil for sufficient time to ensure complete quenching. The quenched iron ball needs to be tempered. The tempering temperature is 320 degrees Celsius, and the tempering method is isothermal tempering, that is, heating the iron ball to the tempering temperature and holding for a period of time to make it reach the required structure and properties. The obtained iron ball is naturally cooled to obtain the required grinding ball.

[0041] Example 2:

[0042] The difference between this embodiment and Example 1 is that the ferrochrome is adjusted to 65 parts.

[0043] Example 3:

[0044] The difference between this embodiment and Example 1 is that the calcium tungstate is adjusted to 1 part.

[0045] Example 4:

[0046] The difference between this embodiment and Example 1 is that the ferrochrome is adjusted to 62 parts.

[0047] Example 5:

[0048] The difference between this embodiment and Example 1 is that the aluminum is adjusted to 3 parts.

[0049] Example 6:

[0050] The difference between this embodiment and Example 1 is that the ferrosilicon is adjusted to 6 parts.

[0051] Example 7:

[0052] The difference between this embodiment and Example 1 is that the ferromanganese is adjusted to 4 parts.

[0053] Example 8:

[0054] The difference between this embodiment and Example 1 is that the magnet is adjusted to 4 parts.

[0055] Example 9:

[0056] The difference between this embodiment and Example 1 is that the tungsten-molybdenum alloy is adjusted to 3 parts.

[0057] Example 10:

[0058] The difference between this embodiment and Example 1 is that the silicon carbide fiber is adjusted to 2 parts.

[0059] Example 11:

[0060] The difference between this embodiment and Example 1 is that the copper is adjusted to 2 parts.

[0061] Example 12:

[0062] The difference between this example and Example 1 is that the calcium tungstate is adjusted to 0.6 parts.

[0063] Example 13:

[0064] The difference between this example and Example 1 is that the ferrochrome is adjusted to 63 parts.

[0065] Example 14:

[0066] The difference between this example and Example 1 is that the aluminum is adjusted to 2.5 parts.

[0067] Example 15:

[0068] The difference between this example and Example 1 is that the ferrosilicon is adjusted to 5.5 parts.

[0069] Example 16:

[0070] The difference between this example and Example 1 is that the ferromanganese is adjusted to 3 parts.

[0071] Example 17:

[0072] The difference between this example and Example 1 is that the magnet is adjusted to 3.5 parts.

[0073] Example 18:

[0074] The difference between this example and Example 1 is that the tungsten-molybdenum alloy is adjusted to 2.5 parts.

[0075] Example 19:

[0076] The difference between this example and Example 1 is that the silicon carbide fiber is adjusted to 1.5 parts.

[0077] Example 20:

[0078] The difference between this example and Example 1 is that the copper is adjusted to 1.5 parts.

[0079] On the basis of the above examples, in order to verify the difference in the performance of the grinding balls from that of the traditional grinding balls, a series of performance tests were carried out on the new grinding balls. The test methods are as follows:

[0080] Prepare materials: 500 new grinding balls made from Example 1, with a diameter of 3 cm; 500 bainitic ductile iron grinding balls in Control Group 1, with the same size as the new grinding balls; 500 chromium alloy cast iron grinding balls in Control Group 2, with the same size as the new grinding balls; work-piece materials to be ground, such as 30 cubic steel pieces with a length of 20 cm and a width of 20 cm; grinding fluid.

[0081] Equipment Preparation: Three ball mills of the same model and specification, hardness tester, electronic balance, timer, dimension measuring equipment, surface roughness detecting equipment, microscope.

[0082] Test Procedures: S1. Measure the hardness of the new grinding balls and traditional grinding balls respectively using a hardness tester, record the data, and calculate the average value; S2. Weigh the initial masses of the new grinding balls, Control Group 1, and Control Group 2 respectively, and record the data; S3. Divide the workpiece materials to be ground into three equal parts and place them into the three ball mills respectively, ensuring that the workpiece surfaces are smooth and free of defects; S4. Add equal amounts of grinding fluid into the three ball mills respectively; S5. Add the new grinding balls, Control Group 1, and Control Group 2 into the three ball mills respectively, and control the same grinding parameters; S6. After the grinding test is completed, clean the new grinding balls, Control Group 1, and Control Group 2 respectively, weigh the masses again, and record the data; S7. Randomly check the wear degrees of 10 new grinding balls, 10 grinding balls of Control Group 1, and 10 grinding balls of Control Group 2 respectively using a microscope, record the inspection results and calculate the average value; S8. Check the grinding effects on the surfaces of each workpiece respectively, measure the surface roughness and grinding depth after grinding, record the data, and calculate the average value.

[0083] Test Results: Attached Figure 1 It is the data table of the test results. It is not difficult to see from the table data that the hardness of the new grinding balls is 65HRC, higher than 60HRC and 62HRC of the traditional grinding balls. The mass loss of the new grinding balls is lower than that of the traditional grinding balls, indicating that the new grinding balls have better wear resistance. In addition, the grinding depth of the new grinding balls on the workpiece is 0.5 mm, higher than 0.3 mm and 0.4 mm of the traditional grinding balls, and the surface roughness of the new grinding balls after grinding is 0.8 μm, lower than 1.2 μm and 1.5 μm of the traditional grinding balls. These results indicate that the grinding efficiency and grinding quality of the new grinding balls are also better than those of the traditional grinding balls.

[0084] The grinding balls prepared by the present application are harder than the traditional grinding balls. The high hardness enables the new grinding balls to more effectively resist wear and deformation, extend the service life, and have better wear resistance, which can reduce material loss during the grinding process, improve the service life and economic benefits, and can effectively shorten the grinding time and save energy when grinding the same workpiece.

[0085] In summary, the grinding balls prepared by the present application show obvious advantages in terms of hardness, wear resistance, and grinding efficiency. These technical advantages make the grinding balls have a broader application prospect in the industrial processing field and can provide a more efficient and economical grinding solution.

[0086] Although exemplary embodiments of the present disclosure have been described, those skilled in the art should understand that various changes and modifications can be made to the exemplary embodiments of the present disclosure without departing from the spirit and scope of the present disclosure in essence. Therefore, all changes and modifications are included within the protection scope of the present disclosure defined by the claims. The present disclosure is defined by the appended claims, and equivalents of these claims are also included.

Claims

1. An energy-saving grinding ball, characterized in that, The mass percentages of the respective components are as follows: 60 - 65 parts of ferrochrome, 1 - 2 parts of zirconia nanoparticles, 3 - 6 parts of zirconia microparticles, 0.3 - 1 part of calcium tungstate, 3 - 5 parts of high - carbon steel, 5 - 6 parts of ferrosilicon, 2 - 3 parts of aluminum, 2 - 4 parts of ferromanganese, 3 - 4 parts of magnet, 2 - 3 parts of tungsten - molybdenum alloy, 1 - 2 parts of silicon carbide fiber, 1 - 2 parts of copper; the chromium content of the ferrochrome is 60% - 65%, and the iron content is 35% - 40%; the zirconia nanoparticles are spherical or quasi - spherical zirconia particles with a diameter of 80 - 90 nanometers; the zirconia microparticles are irregular zirconia particles with a diameter of 1 - 3 micrometers; the calcium tungstate is in the form of a 100 - mesh powder; the magnet is in powder form; the tungsten - molybdenum alloy is spherical tungsten - molybdenum alloy powder; the silicon carbide fiber is 1 - 3 centimeters long and has a diameter of 10 - 20 micrometers.

2. A method for preparing the energy-saving grinding balls of claim 1, characterized in that, It includes the following steps: Step 1, prepare materials, and prepare materials according to the ratio. Step 2, pre - treatment, dry the zirconia nanoparticles, zirconia microparticles, calcium tungstate, high - carbon steel, ferrosilicon, aluminum, ferromanganese, magnet, tungsten - molybdenum alloy, silicon carbide fiber and copper to remove impurities and moisture. Step 3: Mixing, mix the zirconia nanoparticles, zirconia microparticles, calcium tungstate, tungsten - molybdenum alloy, and silicon carbide fiber using a blender to form a mixture for standby. The mixing time is not less than 30 minutes, and the rotation speed is not less than 300 revolutions per minute. Step 4, heat the ferrochrome to 1500 - 1600 degrees Celsius until it is in a molten state, then sequentially add high - carbon steel, ferrosilicon, aluminum and ferromanganese and heat to 1700 - 1800 degrees Celsius. The raw materials are fully melted to form a uniform molten liquid. Then add the mixture formed in Step 3 and the magnet and stir to make the molten liquid and the mixture evenly mixed. Step 5, lower the temperature of the molten liquid to 1200 degrees and pour it into a casting ladle for casting. Step 6, start quenching when the temperature of the iron balls obtained by casting in Step 4 drops to 800 - 900 degrees Celsius. The quenching medium is quenching oil, and its temperature should be controlled below 80 degrees Celsius to ensure rapid cooling and good quenching effect. The iron balls stay in the quenching oil for enough time to ensure complete quenching. The quenched iron balls need to be tempered. The tempering temperature is 320 degrees Celsius, and the tempering method is isothermal tempering, that is, heat the iron balls to the tempering temperature and hold for a period of time to achieve the required structure and properties. Step 7, naturally cool the iron balls obtained in Step 6 to room temperature to obtain grinding balls.

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