A method for preparing cast grinding balls for building materials

Abstract

The invention relates to the technical field of casting grinding ball preparation, and discloses a method for preparing casting grinding balls for building materials, the method comprising preparing raw materials, smelting, pouring, quenching, cleaning, surface treatment and quality inspection, wherein the prepared raw materials include collecting according to the chemical composition ratio: C: 2.8-3.3%, Si: ≤1.2%, Mn: 0.5-0.9%, Cr: 12-15%, S: ≤0.06%, P: ≤0.10%. In the method for preparing casting grinding balls for building materials, accurate component control is the basis for ensuring the performance of casting balls, especially the control of chromium content, which can significantly improve the wear resistance and corrosion resistance of casting balls, ensure the stability and consistency of casting balls in subsequent processing by strictly controlling the raw material components, improve the quality of final products, high temperature smelting ensures the complete melting and uniform mixing of all materials, deoxidation treatment and slag removal treatment remove impurities in the melt, improve the purity of the melt, and multi-stage quenching ensures the uniformity of the internal structure of the casting balls.

Description

Technical Field

[0001] The invention relates to the technical field of casting grinding ball preparation, in particular to a method for preparing casting grinding balls for building materials. Background Art

[0002] Cast grinding balls are an important wear-resistant material widely used in building materials, mining, cement, electric power and other industries. Their main function is to crush and grind materials by rolling and impacting in grinding equipment (such as ball mills). The performance of cast grinding balls directly affects the grinding efficiency and the operating cost of the equipment. Therefore, the preparation of high-quality cast grinding balls is the key to improving production efficiency and reducing costs. However, in the traditional method, a large amount of oil stains will remain on the cast balls during the quenching process. These oil stains not only affect the surface quality of the cast balls, but also pollute the building materials products and affect the quality of the final products. In addition, the cast balls prepared by the traditional method have poor hardness and wear resistance, which affects the service life and performance of the cast balls. Summary of the invention

[0003] The purpose of this section is to summarize some aspects of embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the specification abstract and the invention title of this application to avoid blurring the purpose of this section, the specification abstract and the invention title, and such simplifications or omissions cannot be used to limit the scope of the present invention.

[0004] To achieve the above object, the present invention provides the following technical solutions:

[0005] A method for preparing cast grinding balls for building materials, the method comprising:

[0006] Prepare raw materials, smelting, pouring, quenching, cleaning, surface treatment and quality inspection.

[0007] As a further solution of the present invention: the preparation of raw materials includes,

[0008] Collected by chemical composition ratio: C: 2.8-3.3%, Si: ≤1.2%, Mn: 0.5-0.9%, Cr: 12-15%, S: ≤0.06%, P: ≤0.10%.

[0009] As a further embodiment of the present invention: the smelting comprises:

[0010] Add scrap steel, ferrochrome, ferromanganese, carburizer and other alloys and auxiliary materials into the smelting furnace in sequence and heat to above 1500℃;

[0011] Use a pre-furnace chemical composition analyzer to detect melt composition;

[0012] 2 minutes before leaving the furnace, add 0.4-0.7kg aluminum ingot for deoxidation treatment to remove oxide impurities in the melt;

[0013] Pour the melt into the transfer ladle, skim off the slag and remove the surface scum.

[0014] As a further solution of the present invention: the pouring includes,

[0015] Control the pouring temperature between 1380℃-1480℃ and pour the melt into the preheated metal mold.

[0016] As a further solution of the present invention: the quenching includes:

[0017] Use "oil-like" quenching liquid, mixed with water in a ratio of 1:8 for quenching;

[0018] 0.5% environmentally friendly rust inhibitor and 0.3% high-efficiency coolant are added to the "oil-like" quenching liquid;

[0019] The environmentally friendly rust preventive is a plant extract, and the high-efficiency coolant is a nano-particle dispersion.

[0020] As a further solution of the present invention: the quenching process also includes:

[0021] The cast ball is placed in a quenching furnace and quenched in multiple stages according to the following temperature ranges:

[0022] The first temperature zone is 550℃-600℃, keep warm for 20 minutes; the second temperature zone is 650℃-750℃, keep warm for 20 minutes;

[0023] The third temperature zone is 800℃-900℃, keep warm for 20 minutes; the fourth temperature zone is 950℃-980℃, keep warm for 20 minutes;

[0024] The total holding time is 10 hours.

[0025] As a further embodiment of the present invention: the cleaning step comprises:

[0026] Put the quenched cast ball into the spiral cleaning machine, turn on the ultrasonic cleaning function, and use the high-pressure spray system to spray clean water to thoroughly rinse the surface of the cast ball;

[0027] The wastewater generated during the cleaning process is collected, mixed with the quenching liquid in a certain proportion, and used again in the quenching process.

[0028] As a further solution of the present invention: the spiral cleaning machine includes an ultrasonic cleaning unit and a high-pressure spray unit, wherein the frequency range of the ultrasonic cleaning unit is 20-100kHz, and the pressure range of the high-pressure spray unit is 10-30MPa.

[0029] As a further solution of the present invention: the surface treatment step comprises:

[0030] The cleaned casting ball is subjected to surface polishing to further improve the surface finish;

[0031] Polishing time is 2-5 minutes.

[0032] As a further solution of the present invention: the quality detection step includes:

[0033] Use X-ray flaw detector and hardness tester to check the quality of cast balls to ensure there are no cracks and the hardness meets the standard.

[0034] As a further solution of the present invention: the cast ball is cleaned immediately after quenching, the cleaning time is 5-10 minutes, the final hardness range of the cast ball is HRC 58-62, and the surface finish reaches Ra0.8μm or less.

[0035] Compared with the prior art, the present invention has the following beneficial effects:

[0036] Precise composition control is the basis for ensuring the performance of cast balls, especially the control of chromium content, which can significantly improve the wear resistance and corrosion resistance of cast balls. By strictly controlling the composition of raw materials, the stability and consistency of cast balls in subsequent processing are ensured, and the quality of final products is improved. High-temperature smelting ensures the complete melting and uniform mixing of all materials. Deoxidation and slag removal remove impurities in the melt and improve the purity of the melt. Multi-stage quenching ensures the uniformity of the internal structure of the cast ball. The addition of environmentally friendly rust inhibitors and high-efficiency coolants improves the quenching effect and the anti-corrosion performance of the cast ball. Ultrasonic cleaning and high-pressure spraying systems ensure the thorough cleaning of the surface of the cast ball. The recycling of wastewater reduces the waste of water resources. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 The present invention is a schematic diagram of a process flow of a method for preparing cast grinding balls for building materials. DETAILED DESCRIPTION

[0038] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and understandable, the specific implementation modes of the present invention are described in detail below in conjunction with the accompanying drawings.

[0039] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0040] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0041] Example

[0042] See also Figure 1 , is an embodiment of the present invention, which provides a method for preparing a cast grinding ball for building materials, comprising:

[0043] Prepare raw materials: Collect raw materials according to the following chemical composition ratios:

[0044] C: 3.0%;

[0045] Si: 1.0%;

[0046] Mn: 0.7%;

[0047] Cr: 13.5%;

[0048] S: 0.05%;

[0049] P: 0.08%;

[0050] Raw materials include scrap steel, ferrochrome, ferromanganese, carburizer and other alloys and auxiliary materials;

[0051] Smelting:

[0052] Add the above raw materials into the medium frequency induction furnace in sequence and heat to 1550℃ to ensure that all materials are completely melted and evenly mixed;

[0053] Use a chemical composition analyzer in front of the furnace to detect the melt composition to ensure that it meets the predetermined ratio;

[0054] 2 minutes before leaving the furnace, add 0.5kg aluminum ingot for deoxidation treatment to remove oxide impurities in the melt;

[0055] Pour the melt into the transfer ladle, skim off the slag and remove the surface scum;

[0056] pouring:

[0057] Control the pouring temperature at 1400°C and pour the melt into the preheated metal mold;

[0058] Quenching:

[0059] Use "oil-like" quenching liquid, mixed with water at a ratio of 1:8, add 0.5% plant extract rust inhibitor and 0.3% nanoparticle dispersion high-efficiency coolant to the quenching liquid;

[0060] The cast ball is placed in a quenching furnace and quenched in multiple stages according to the following temperature ranges:

[0061] The first temperature zone is 550℃, keep warm for 20 minutes;

[0062] The second temperature zone is 650℃, keep warm for 20 minutes;

[0063] The third temperature zone is 850℃, keep warm for 20 minutes;

[0064] 960℃ in the fourth temperature zone, keep warm for 20 minutes;

[0065] The total holding time is 10 hours;

[0066] Cleaning:

[0067] The quenched cast ball was placed in a spiral cleaning machine, the ultrasonic cleaning function (frequency was 50kHz) was turned on, and the high-pressure spray system (pressure was 20MPa) was used to spray clean water to thoroughly rinse the surface of the cast ball. The cleaning time was 8 minutes;

[0068] The wastewater generated during the cleaning process is collected, mixed with the quenching liquid in a 1:1 ratio, and used again in the quenching process;

[0069] Surface treatment:

[0070] The cleaned casting ball is subjected to surface polishing for 3 minutes to further improve the surface finish;

[0071] Quality Inspection:

[0072] Use X-ray flaw detector and hardness tester to inspect the quality of cast balls to ensure there are no cracks and the hardness meets the standard;

[0073] The final hardness of the cast ball ranges from HRC 60, and the surface finish reaches Ra 0.7μm;

[0074] Table: Performance comparison between the prior art and the preparation method of the present invention

[0075]

[0076] Tabular data analysis:

[0077] By comparing the data in the above table, it can be seen that the preparation method of the present invention is superior to the prior art in many aspects, and the specific analysis is as follows:

[0078] Raw material cost and quenching liquid cost:

[0079] The raw material cost of the method of the present invention is 4,800 yuan / ton, which is 4.00% lower than 5,000 yuan / ton of the prior art;

[0080] The cost of quenching liquid is 1800 yuan / ton, which is 10.00% lower than the 2000 yuan / ton of the prior art;

[0081] The cost reduction is mainly due to the low cost of the environmentally friendly rust preventive and the high-efficiency coolant used in the method of the present invention, and the recycling of resources reduces the waste of materials;

[0082] Surface oil stain amount after quenching:

[0083] The amount of oil stain on the surface after quenching by the method of the present invention is only 20mg / m 2 , while the existing technology is 150mg / m 2 , a decrease of 86.67%;

[0084] The "oil-like" quenching liquid and the high-efficiency cleaning ability of the spiral cleaning machine used in the method of the present invention ensure the cleanliness of the surface of the cast ball and avoid contamination of the building material product;

[0085] Hardness and surface finish:

[0086] The hardness of the cast ball prepared by the method of the present invention is HRC 60, which is 9.09% higher than HRC 55 of the prior art;

[0087] The surface finish is Ra 0.7μm, which is 53.33% higher than the existing technology Ra 1.5μm;

[0088] Higher hardness and better surface finish make the cast ball have better wear resistance and lower friction loss during use, extending the service life;

[0089] Abrasion resistance:

[0090] The wear resistance of the cast ball prepared by the method of the present invention is 0.8 g / 1000 m, which is 33.33% lower than 1.2 g / 1000 m of the prior art.

[0091] It shows that the cast ball prepared by the method of the present invention has less wear in actual use and has higher durability;

[0092] Production cycle:

[0093] The production cycle of the method of the present invention is 10 hours, which is 16.67% shorter than the 12 hours of the prior art;

[0094] The method of the present invention optimizes the quenching and cleaning steps, thereby improving production efficiency;

[0095] Wastewater generation:

[0096] The wastewater generated by the method of the present invention is 50L / 1000kg, which is 50.00% less than 100L / 1000kg of the prior art;

[0097] Thanks to the recycling of wastewater, not only the waste of water resources is reduced, but also the pollution to the environment is reduced.

[0098] In summary, the method of the present invention shows significant advantages in terms of raw material cost, quenching liquid cost, surface oil content, hardness, surface finish, wear resistance, production cycle and wastewater generation. The data fully proves the innovation and superiority of the method of the present invention and has important practical application value.

[0099] Importantly, it should be noted that the construction and arrangement of the present application shown in a plurality of different exemplary embodiments are only exemplary. Although only a few embodiments are described in detail in this disclosure, it should be readily understood by those who refer to this disclosure that many modifications are possible (e.g., the size, scale, structure, shape and proportion of various elements, and parameter values ​​(e.g., temperature, pressure, etc.), installation arrangement, use of materials, color, directional changes, etc.) without substantially departing from the novel teachings and advantages of the subject matter described in the application. For example, the element shown as integrally formed can be composed of multiple parts or elements, the position of the element can be inverted or otherwise changed, and the nature or number or position of the discrete element can be changed or changed. Therefore, all such modifications are intended to be included in the scope of the present invention. The order or sequence of any process or method steps can be changed or reordered according to alternative embodiments. In the claims, any "device plus function" clause is intended to cover the structure of performing the function described herein, and is not only structurally equivalent but also equivalent structure. Without departing from the scope of the present invention, other replacements, modifications, changes and omissions can be made in the design, operating conditions and arrangement of the exemplary embodiments. Therefore, the invention is not limited to a specific embodiment, but extends to numerous modifications still falling within the scope of the appended claims.

[0100] Additionally, in order to provide a concise description of exemplary embodiments, all features of an actual embodiment (ie, those features that are not relevant to the best mode presently contemplated for carrying out the invention or those that are not relevant to implementing the invention) may not be described.

[0101] It will be appreciated that in the development of any actual implementation, as in any engineering or design project, numerous implementation-specific decisions may be made. Such a development effort may be complex and time-consuming, but will be a routine task of design, fabrication, and production for those of ordinary skill having the benefit of this disclosure without undue experimentation.

[0102] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A method for preparing cast grinding balls for building materials, characterized in that: The preparation method comprises: Prepare raw materials, smelting, pouring, quenching, cleaning, surface treatment and quality inspection.

2. The method for preparing a cast grinding ball for building materials according to claim 1, characterized in that: The prepared raw materials include: Collected by chemical composition ratio: C: 2.8-3.3%, Si: ≤1.2%, Mn: 0.5-0.9%, Cr: 12-15%, S: ≤0.06%, P: ≤0.10%.

3. The method for preparing a cast grinding ball for building materials according to claim 1, characterized in that: The smelting includes: Add scrap steel, ferrochrome, ferromanganese, carburizer and other alloys and auxiliary materials into the smelting furnace in sequence and heat to above 1500℃; Use a pre-furnace chemical composition analyzer to detect melt composition; 2 minutes before leaving the furnace, add 0.4-0.7kg aluminum ingot for deoxidation treatment to remove oxide impurities in the melt; Pour the melt into the transfer ladle, skim off the slag and remove the surface scum.

4. The method for preparing a cast grinding ball for building materials according to claim 1, characterized in that: The pouring comprises: Control the pouring temperature between 1380℃-1480℃ and pour the melt into the preheated metal mold.

5. The method for preparing a cast grinding ball for building materials according to claim 1, characterized in that: The quenching includes: Use "oil-like" quenching liquid, mixed with water in a ratio of 1:8 for quenching; 0.5% of environmentally friendly rust inhibitor and 0.3% of high-efficiency coolant are added to the "oil-like" quenching liquid.

6. The method for preparing a cast grinding ball for building materials according to claim 5, characterized in that: The quenching process also includes: The cast ball is placed in a quenching furnace and quenched in multiple stages according to the following temperature ranges: The first temperature zone is 550℃-600℃, keep warm for 20 minutes; the second temperature zone is 650℃-750℃, keep warm for 20 minutes; The third temperature zone is 800℃-900℃, keep warm for 20 minutes; the fourth temperature zone is 950℃-980℃, keep warm for 20 minutes; The total holding time is 10 hours.

7. The method for preparing a cast grinding ball for building materials according to claim 1, characterized in that: The cleaning step comprises, Put the quenched cast ball into the spiral cleaning machine, turn on the ultrasonic cleaning function, and use the high-pressure spray system to spray clean water to thoroughly rinse the surface of the cast ball; The wastewater generated during the cleaning process is collected, mixed with the quenching liquid in a certain proportion, and used again in the quenching process.

8. The method for preparing a cast grinding ball for building materials according to claim 7, characterized in that: The spiral cleaning machine comprises an ultrasonic cleaning unit and a high-pressure spraying unit, wherein the frequency range of the ultrasonic cleaning unit is 20-100kHz, and the pressure range of the high-pressure spraying unit is 10-30MPa.

9. The method for preparing a cast grinding ball for building materials according to claim 1, characterized in that: The surface treatment step comprises: The cleaned casting ball is subjected to surface polishing to further improve the surface finish; Polishing time is 2-5 minutes.

10. The method for preparing a cast grinding ball for building materials according to claim 1, characterized in that: The quality inspection step includes: The quality of the cast balls is inspected using an X-ray flaw detector and a hardness tester.

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