Manufacturing method of wear-resistant steel ball test marking ball for ball mill

Abstract

The invention belongs to the technical field of metal processing forming, and relates to a wear-resistant steel ball test marking ball, in particular to a manufacturing method of the wear-resistant steel ball test marking ball for a ball mill. The method comprises the following steps that S1, the temperature of a ball blank is kept to be 960 DEG C or above; s2, the temperature is maintained, and the ball blank is placed on the semicircular female die; s3, clamping a thin steel section, and pressing the thin steel section into the ball blank along the vertical diameter of the ball blank by the press machine; and S4, the ball blank obtained in the S3 is subjected to rolling forming through a steel ball rolling machine, then heat treatment is conducted, and the wear-resistant steel ball test marking ball for the ball mill is obtained. According to the method, the test ball mark of the wear-resistant steel ball is preset in the ball blank, the influence of drilling on the overall performance of the wear-resistant steel ball is effectively avoided, meanwhile, the mark ball can have a clear and obvious mark at the last stage of the service life through the embedded mark, and the defects of an existing marking method are properly overcome.

Description

Technical Field

[0001] The present application belongs to the technical field of metal processing and forming, and relates to a wear-resistant steel ball test marking ball, and specifically to a method for manufacturing a wear-resistant steel ball test marking ball for a ball mill. Background Art

[0002] A ball mill is a common piece of industrial equipment. It primarily grinds materials into finer particles or even mixes them by rotating wear-resistant steel balls within a cylinder, grinding, rubbing, and impacting the material. Wear-resistant steel balls are typically made of wear-resistant steel, offering excellent hardness and impact resistance, facilitating material grinding. Ball mills offer advantages such as high efficiency and stable grinding performance, making them widely used in industries such as metallurgy, mineral processing, and building materials.

[0003] Wear-resistant steel balls are the primary consumables of ball mills. Their production process includes the following steps: 1. Raw material preparation; 2. Ball blank preparation; 3. Rough hot forming; 4. Ball blank heat treatment; 5. Forming. The formed steel balls undergo surface treatment and are ready for inspection and packaging.

[0004] Due to the fierce competition in the wear-resistant steel ball market, it is common for multiple wear-resistant steel ball suppliers to provide wear-resistant steel balls to the same buyer. In this case, in order to select the best, the buyer will require multiple suppliers to simultaneously load their wear-resistant steel balls into the same normally operating ball mill to compare their performance. To this end, in order to distinguish their ball mill balls from those of other suppliers, multiple suppliers often drill different numbers of blind holes in their wear-resistant steel balls, or the buyer will specify that each supplier drill blind holes in its wear-resistant steel balls for easy identification.

[0005] However, the method of drilling blind holes in wear-resistant steel balls for marking and distinguishing them has the following disadvantages: due to the high hardness and carbon content of wear-resistant steel balls, drilling blind holes in the finished wear-resistant steel balls after heat treatment is very difficult. Not only is drilling time and labor consuming, but it also consumes a lot of drill bits, resulting in high processing costs. Therefore, in the prior art, some suppliers choose to drill blind holes before heat treatment of the ball blanks, that is, during the rough hot forming process, to reduce the processing difficulty.

[0006] However, drilling holes in unheat-treated ball blanks will cause large internal stresses to appear at the drilled holes of the semi-finished wear-resistant steel balls after the ball blanks undergo the heat treatment process. Ball drop tests on such marked wear-resistant steel balls have shown that they are very likely to crack or fall off at the drilled holes. In other words, this drilling method will reduce the performance of the wear-resistant steel balls and cannot truly reflect the actual quality of the products. At the same time, different buyers have different performance requirements for wear-resistant steel balls. If the buyer has high requirements for the working life of the wear-resistant steel balls, the blind holes opened on the steel balls will be difficult to find as the steel balls wear in the ball mill.

[0007] Therefore, it is necessary to propose a method for preparing a test marking ball with high production efficiency, low production cost, and no reduction in the performance of the steel ball. Summary of the Invention

[0008] In order to improve the various deficiencies of the test marker ball preparation method in the related art, the present application provides a method for making a wear-resistant steel ball test marker ball for a ball mill.

[0009] The present application provides a method for manufacturing a wear-resistant steel ball test marking ball for a ball mill, which adopts the following technical solution: A method for manufacturing a wear-resistant steel ball test marking ball for a ball mill comprises the following steps: S1, maintaining the temperature of the ball blank after hot working rough forming to above 960°C; S2, maintain the temperature in step S1, clamp the ball blank by fixture, and place the ball blank on the semicircular die of press workbench; S3. A thin steel segment is clamped by a fixture so that the thin steel segment is perpendicular to the upper plane of the semicircular die. A press is used to press the thin steel segment into the ball blank along the lead vertical diameter of the ball blank. When the thin steel segment is completely inserted into the ball blank, the downward pressure column of the press is reset. S4, rolling the ball blank of S3 into shape by a steel ball rounding machine, and then performing a heat treatment to obtain the wear-resistant steel ball test marking ball for the ball mill.

[0010] By adopting the above-mentioned technical solution, the present application presets the test ball mark of the wear-resistant steel ball in the ball blank, effectively avoiding the influence of drilling on the overall performance of the wear-resistant steel ball. At the same time, the "embedded" mark of the present application enables the marked ball to have clear and obvious marks in the final stage of its service life, properly solving the various problems of the existing marking method.

[0011] Preferably, in steps S2 and S3, the clamping is performed by a robot.

[0012] By adopting the above technical solution, the robot arm has higher clamping stability and more accurate clamping precision compared to the operator holding the clamp.

[0013] Preferably, in step S2, the clamping position of the manipulator is located in the middle of the ball blank, and the clamping width of the manipulator on the ball blank is 1 / 3 to 1 / 2 of the diameter of the wear-resistant steel ball.

[0014] By adopting the above technical solution, the above clamping method is conducive to stably placing the ball blank on the semicircular die, reducing the possibility of the steel ball accidentally falling due to clamping reasons.

[0015] Preferably, in step S2, the depth of the center of the semicircular die is less than or equal to 1 / 3 of the diameter of the wear-resistant steel ball.

[0016] By adopting the above technical solution, when the depth of the center of the die is less than or equal to 1 / 3 of the diameter of the steel ball, the contact area between the die and the steel ball is smaller, which can achieve a more uniform stress distribution, avoid excessive stress concentration on the contact point between the die and the steel ball, and reduce possible deformation and breakage; at the same time, the smaller die depth makes it easier to place and remove the steel ball blank, thereby improving preparation efficiency and operational convenience.

[0017] Preferably, in step S3, the clamping position of the manipulator is located in the middle of the thin steel segment, and the clamping width of the manipulator on the thin steel segment is 1 / 3 to 1 / 2 of the length of the thin steel segment.

[0018] By adopting the above technical solution, the above clamping method is conducive to stably embedding the thin steel segment into the ball blank.

[0019] Preferably, the diameter of the thin steel segment is 1 / 40 to 1 / 16 of the diameter of the wear-resistant steel ball, and the length is 1 / 20 to 1 / 5 of the diameter of the wear-resistant steel ball.

[0020] By adopting the above technical solution, if the size of the thin steel segment is too large, it will affect the formation of the wear-resistant steel ball, causing excessive local stress inside the steel ball, resulting in damage or fragmentation of the steel ball; if the size of the thin steel segment is too small, it will not provide a clear identification function. Therefore, when the diameter and length of the thin steel segment are within the above range, it will not affect the performance of the steel ball and still provide a clear identification function.

[0021] Preferably, the top and bottom of the thin steel segment are both convex arc-shaped, and the curvature radius of the arc is the same as the radius of the wear-resistant steel ball.

[0022] By adopting the above technical solution, when the top and bottom of the thin steel segment meet the above conditions, the thin steel segment can be inserted into the steel ball without distinguishing the head and the tail, saving working time.

[0023] Preferably, the thin steel segment is made of T8 tool steel.

[0024] By adopting the above technical solution, T8 tool steel and steel balls have similar thermal expansion coefficients and mechanical properties, so that during the operation of the ball mill, due to similar characteristics, the thermal expansion and contraction or mechanical stress between T8 tool steel and steel balls is relatively small.

[0025] Preferably, all the processes of steps S2 and S3 are carried out when the temperature of the pellet is higher than 960°C.

[0026] By adopting the above technical solution, the steel has good plasticity and deformation properties at high temperatures. Keeping the ball billet at a high temperature of more than 960°C can make the steel have sufficient plasticity, so that the steel can be more easily plastically deformed during the process of embedding the thin steel segment, ensuring the formation of the mark and the smooth progress of the processing process, and also reducing the probability of local stress and deformation caused by thermal expansion and contraction.

[0027] In summary, this application has the following beneficial effects: 1. This application presets the test ball mark of the wear-resistant steel ball in the ball blank, effectively avoiding the impact of drilling on the overall performance of the wear-resistant steel ball. At the same time, the "embedded" mark of this application allows the marked ball to have clear and obvious marks even in the final stage of its service life, properly solving various problems of existing marking methods; In addition, the present application can conveniently place multiple thin steel segments with the same or different cross-sectional shapes on the sphere of the wear-resistant steel ball by changing the program of the control elements such as the press and the manipulator, and produce a variety of wear-resistant steel balls with clear markings and significant distinguishing features for comparative experiments. It can be conveniently used for experimental comparison of wear-resistant steel balls between multiple production suppliers, and can also be used for experimental comparison between different batches of wear-resistant steel balls made of multiple materials by the same manufacturer, thereby providing convenient and effective conditions for experimental research.

[0028] 2. In this application, the depth of the center of the semicircular die is less than or equal to 1 / 3 of the diameter of the wear-resistant steel ball. When the depth of the center of the die is less than or equal to 1 / 3 of the diameter of the steel ball, the contact area between the die and the steel ball is smaller, which can achieve a more uniform stress distribution, avoid excessive stress concentration on the contact point between the die and the steel ball, and reduce possible deformation and breakage; at the same time, the smaller die depth makes it easier to place and remove the steel ball blank, thereby improving preparation efficiency and operational convenience.

[0029] 3. The diameter of the thin steel segment of the present application is 1 / 40~1 / 5 of the diameter of the wear-resistant steel ball, and the length is 1 / 20~1 / 5 of the diameter of the wear-resistant steel ball. When the diameter and length of the thin steel segment are within the above range, it will not affect the performance of the steel ball and can play an obvious identification role.

[0030] 4. The material of the fine steel segment of the present application is T8 tool steel. T8 tool steel and steel balls have similar thermal expansion coefficients and mechanical properties. Therefore, during the operation of the ball mill, due to similar characteristics, the thermal expansion and contraction or mechanical stress between T8 tool steel and steel balls is relatively small.

[0031] 5. All the processes of steps S2 and S3 of the present application are carried out when the temperature of the ball blank is higher than 960°C, so that the steel has sufficient plasticity, so that the steel can be more easily plastically deformed during the embedding of the thin steel segment, ensuring the formation of the mark and the smooth progress of the processing, and also reducing the probability of local stress and deformation caused by thermal expansion and contraction. DETAILED DESCRIPTION

[0032] The present invention is further described in detail below with reference to the following examples: The diameter of the steel ball prepared in the present invention is 80 mm. Example

[0033] Example 1 provides a method for manufacturing a wear-resistant steel ball test marking ball for a ball mill, comprising the following steps: S1. Raw material preparation; S2, ball blank preparation; S3, hot working rough forming; S4, maintaining the temperature of the ball blank after hot working rough forming to 960°C; S5, the temperature among the maintenance step S4, by manipulator one clamping ball base, and ball base is placed on the semicircular die of press workbench; Manipulator one clamping and the middle part of ball base, and clamping width is 8 / 3mm, and the center depth of semicircular die is 8 / 3mm, and the downward pressing column of press machine is corresponding with semicircular die and perpendicular to the upper plane of semicircular die; S6, the temperature in maintenance step S4, clamp a thin steel section by manipulator two, make the thin steel section perpendicular to the upper plane of semicircular die; The diameter of the thin steel section is 2mm, and the length is 4mm, and both ends are convex arcuate surfaces, and the radius of curvature of the arcuate surface is identical with the radius of wear-resistant steel ball; Manipulator two is clamped in the middle part of the thin steel section, and the clamping width is 4 / 3mm; Pressing machine presses the thin steel section into the ball billet along the lead vertical diameter of the ball billet; When the top of the thin steel section coincides with the ball billet, remove the manipulator, and the pressing column of press machine is reset; S7. The ball blank of S6 is rolled into shape by a steel ball rounding machine, and then heat treated to obtain a wear-resistant steel ball test marking ball for a ball mill.

[0034] In this embodiment, the material of the thin steel segment is T8 tool steel. In addition, in this embodiment, the processes in steps S1, S2, S3, and S7 have no significant difference from the processes known in the art and are not described in detail here. Example

[0035] Example 2 provides a method for manufacturing a wear-resistant steel ball test marking ball for a ball mill, comprising the following steps: S1. Raw material preparation; S2, ball blank preparation; S3, hot working rough forming; S4, maintaining the temperature of the ball blank after hot working rough forming to 960°C; S5, the temperature among the maintenance step S4, by manipulator one clamping ball base, and ball base is placed on the semicircular die of press workbench; Manipulator one clamping and the middle part of ball base, and clamping width is 3.00mm, and the center depth of semicircular die is 20mm, and the downward pressing column of press machine is corresponding with semicircular die and perpendicular to the upper plane of semicircular die; S6, the temperature in maintenance step S4, clamp a thin steel section by manipulator two, make the thin steel section perpendicular to the upper plane of semicircular die; The diameter of the thin steel section is 3mm, and the length is 10mm, and both ends are convex arcuate surfaces, and the radius of curvature of the arcuate surface is identical with the radius of wear-resistant steel ball; Manipulator two is clamped in the middle part of the thin steel section, and the clamping width is 1.2mm; Press presses the thin steel section into the ball blank along the lead vertical diameter of the ball blank; When the top of the thin steel section coincides with the ball blank, remove the manipulator, and the downward pressure column of press resets; S7. The ball blank of S6 is rolled into shape by a steel ball rounding machine, and then heat treated to obtain a wear-resistant steel ball test marking ball for a ball mill.

[0036] In this embodiment, the material of the thin steel segment is T8 tool steel. In addition, in this embodiment, the processes in steps S1, S2, S3, and S7 have no significant difference from the processes known in the art and are not described in detail here. Example

[0037] Example 3 provides a method for manufacturing a wear-resistant steel ball test marking ball for a ball mill, comprising the following steps: S1. Raw material preparation; S2, ball blank preparation; S3, hot working rough forming; S4, maintaining the temperature of the ball blank after hot working rough forming to 960°C; S5, the temperature among the maintenance step S4, by manipulator one clamping ball base, and ball base is placed on the semicircular die of press workbench; Manipulator one clamping and the middle part of ball base, and clamping width is 4mm, and the center depth of semicircular die is 20mm, and the downward pressing column of press machine is corresponding with semicircular die and perpendicular to the upper plane of semicircular die; S6, the temperature in maintenance step S4, clamp a thin steel section by manipulator two, make the thin steel section perpendicular to the upper plane of semicircular die; The diameter of the thin steel section is 5mm, and the length is 16mm, and both ends are convex arcuate surfaces, and the radius of curvature of the arcuate surface is identical with the radius of wear-resistant steel ball; Manipulator two is clamped in the middle part of the thin steel section, and the clamping width is 8mm; Pressing machine presses the thin steel section into the ball blank along the lead vertical diameter of the ball blank; When the top of the thin steel section coincides with the ball blank, remove the manipulator, and the downward pressure column of press machine is reset; S7. The ball blank of S6 is rolled into shape by a steel ball rounding machine, and then heat treated to obtain a wear-resistant steel ball test marking ball for a ball mill.

[0038] In this embodiment, the material of the thin steel segment is T8 tool steel. In addition, in this embodiment, the processes in steps S1, S2, S3, and S7 have no significant difference from the processes known in the art and are not described in detail here. Comparative Example

[0039] Comparative Example 1 A marking steel ball, the preparation method of which includes 1. raw material preparation; 2. ball blank preparation; 3. hot working rough forming; 4. ball blank heat treatment; 5. forming; in this comparative example, between step 3 and step 4, the steel ball is subjected to blind hole drilling.

[0040] Comparative Example 2 Compared with Example 1, the temperature maintained in step S4 is 950°C. Performance testing

[0041] The above examples and comparative examples were tested for performance, and the results are shown in Table 1:

[0042] Combining the test data with the embodiments and comparative examples, it can be seen that: ① Among Examples 1 to 3, the detection data of Example 2 is the best; ②, Combining Example 1 and Comparative Example 1, all the data of Comparative Example 1 are inferior to those of Example 1, especially the ball drop breakage rate; ③. Combining Example 1 and Comparative Example 2, all the data of Example 1 are better than those of Comparative Example 2.

[0043] Regarding point ①, likely due to the superior gripping width of the manipulator in Example 2 and the specifications of the thin steel segments embedded in the ball blank, under the process conditions of Example 2, the thin steel segments were able to fuse more thoroughly and systematically with the ball blank, and after fusion, the performance of the steel balls was not significantly reduced. Furthermore, the various test data from Examples 1-3 all met the performance parameters of wear-resistant steel balls in the industry, indicating that the marking steel balls prepared from Examples 1-3 fully reflect the performance of wear-resistant steel balls and can be used as marking steel balls.

[0044] Regarding ②, this is because the comparative example 1 drilled a hole on the unheat-treated ball blank, which caused a large internal stress at the drill hole of the semi-finished wear-resistant steel ball after the ball blank heat treatment process. Such a marking wear-resistant steel ball is prone to cracking or large-scale chipping at the drill hole, which will Reducing the performance of wear-resistant steel balls does not truly reflect the actual quality of the product; however, in Example 1, the thin steel segment is embedded in the ball blank, and then integrally formed with the ball blank to form a marking steel ball, which does not cause adverse effects on the steel ball, and its drop ball test data is better.

[0045] Regarding ③, this is because the temperature in Comparative Example 2 was not maintained above 960°C, while the pre-embedding steps of the thin steel segments in Example 1 were all completed at 960°C. Steel has good plasticity and deformation properties at high temperatures. Maintaining the ball billet at a temperature above 960°C can give the steel sufficient plasticity, allowing it to more easily undergo plastic deformation during the embedding of the thin steel segments, ensuring the formation of the mark and the smooth progress of the processing. It also reduces the probability of local stress and deformation caused by thermal expansion and contraction. Conversely, if the ball billet is not maintained above this temperature, the probability of local stress and deformation in the prepared steel ball will increase. Therefore, all test data of Example 1 are better than those of Comparative Example 2.

[0046] This specific embodiment is merely an explanation of the present application and is not a limitation of the present application. After reading this specification, those skilled in the art may make non-creative modifications to the present embodiment as needed, but as long as they are within the scope of the claims of the present application, they are protected by the patent law.

Claims

1. A method for making a wear-resistant steel ball test marking ball for a ball mill, characterized in that: The steps include: S1. Maintain the temperature of the ball blank after hot working rough forming to above 960°C; S2, maintain the temperature in step S1, clamp the ball blank by a fixture, and place the ball blank on the semicircular die of the press workbench; S3, a thin steel section is clamped by a fixture so that the thin steel section is perpendicular to the upper plane of the semicircular die, and a press machine presses the thin steel section into the ball blank along the lead vertical diameter of the ball blank; when the thin steel section just completely enters the ball blank, the downward pressing column of the press machine is reset; S4, rolling the ball blank of S3 into shape by a steel ball rounding machine, and then performing a heat treatment to obtain the wear-resistant steel ball test marking ball for the ball mill.

2. The method for manufacturing a wear-resistant steel ball test marking ball for a ball mill according to claim 1, characterized in that: In steps S2 and S3, the clamping is performed by a robot.

3. The method for manufacturing a wear-resistant steel ball test marking ball for a ball mill according to claim 2, characterized in that: In step S2, the clamping position of the manipulator is located in the middle of the ball blank, and the clamping width of the manipulator on the ball blank is 1 / 3 to 1 / 2 of the diameter of the wear-resistant steel ball.

4. The method for manufacturing a wear-resistant steel ball test marking ball for a ball mill according to claim 2, characterized in that: In step S2, the depth of the center of the semicircular die is less than or equal to 1 / 3 of the diameter of the wear-resistant steel ball.

5. The method for manufacturing a wear-resistant steel ball test marking ball for a ball mill according to claim 2, characterized in that: In step S3, the clamping position of the manipulator is located in the middle of the thin steel segment, and the clamping width of the manipulator on the thin steel segment is 1 / 3 to 1 / 2 of the length of the thin steel segment.

6. The method for manufacturing a wear-resistant steel ball test marking ball for a ball mill according to claim 1, characterized in that: The diameter of the thin steel segment is 1 / 40 to 1 / 16 of the diameter of the wear-resistant steel ball, and the length is 1 / 20 to 1 / 5 of the diameter of the wear-resistant steel ball.

7. The method for manufacturing a wear-resistant steel ball test marking ball for a ball mill according to claim 1, characterized in that: The top and bottom of the thin steel section are both convex arcs, and the curvature radius of the arc is the same as the radius of the wear-resistant steel ball.

8. The method for manufacturing a wear-resistant steel ball test marking ball for a ball mill according to claim 1, characterized in that: The material of the thin steel section is T8 tool steel.

9. The method for manufacturing a wear-resistant steel ball test marking ball for a ball mill according to claim 1, characterized in that: All the processes of steps S2 and S3 are carried out when the temperature of the pellet is higher than 960°C.

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