A method for manufacturing wear-resistant balls

Abstract

This invention provides a method for manufacturing a wear-resistant ball, comprising: S1, prefabricating a plurality of wear-resistant bodies composed of a first wear-resistant material; S2, fabricating a casting mold, forming at least one spherical cavity and a pouring channel connected to the spherical cavity within the mold; S3, fixing the plurality of wear-resistant bodies radially spaced around the center of the spherical cavity within the spherical cavity; S4, casting a second metallic wear-resistant material into the spherical cavity through the pouring channel of the mold to fill the gaps between the plurality of wear-resistant bodies; S5, after cooling, forming a wear-resistant ball blank composed of the cast body and the plurality of wear-resistant bodies, and performing surface treatment on the wear-resistant ball blank after demolding to obtain the finished wear-resistant ball; the wear-resistant ball manufactured by this method is a sphere composed of a plurality of wear-resistant bodies and a cast body, and the wear-resistant bodies reinforce the hardness of the surface and deep layers of the wear-resistant ball along the radial direction of the sphere, so that even if the surface of the wear-resistant ball is slowly worn, its wear resistance will not decrease, thereby improving the overall wear resistance of the wear-resistant ball.

Description

Technical Field

[0001] This invention relates to the field of wear-resistant materials technology, and specifically to a method for manufacturing a wear-resistant ball. Background Technology

[0002] Wear-resistant balls are widely used in industries such as metallurgy and mining, cement and building materials, thermal power generation, flue gas desulfurization, magnetic materials, chemicals, coal-water slurry, pellets, slag, ultrafine powder, fly ash, calcium carbonate, and quartz sand. In recent years, with the rapid development of my country's industry, the consumption of wear-resistant balls has also increased significantly. During the operation of ball mills, wear-resistant balls are among the main wear-prone parts, greatly impacting operating costs. Therefore, improving the wear resistance of wear-resistant balls and extending their service life will generate significant economic benefits.

[0003] Currently, wear-resistant balls are generally manufactured by integrally casting alloy cast iron or ductile iron, resulting in poor wear resistance. To improve their wear resistance, a post-treatment process of quenching is typically used to increase their hardness. However, because wear-resistant balls have a solid structure, quenching only increases the hardness of the surface layer to a certain thickness, and the hardness decreases closer to the center. During use, wear-resistant balls manufactured using current methods gradually lose wear resistance as the surface layer wears down, leading to reduced grinding efficiency. Summary of the Invention

[0004] The purpose of this invention is to solve the problems mentioned in the background art and provide a method for manufacturing a wear-resistant ball. The wear-resistant ball manufactured by this method is a sphere composed of multiple wear-resistant bodies and a cast body. The wear-resistant bodies reinforce the surface and deeper layers of the wear-resistant ball along the radial direction of the sphere, so that even if the surface layer of the wear-resistant ball is gradually worn, its wear resistance will not decrease, thereby improving the overall wear resistance of the wear-resistant ball. The wear-resistant bodies are made of wear-resistant materials that do not require annealing, preferably non-metallic carbon-based or silicon-based wear-resistant materials.

[0005] This invention adopts the following technical solution: a method for manufacturing wear-resistant balls, comprising:

[0006] S1, prefabricated multiple wear-resistant bodies composed of a first wear-resistant material;

[0007] S2, make a casting mold, and form at least one spherical cavity and a pouring channel connected to the spherical cavity in the mold;

[0008] S3, multiple wear-resistant materials are fixed radially and spaced around the center of the spherical mold cavity;

[0009] S4, the second metal wear-resistant material is poured into the spherical mold cavity through the pouring channel of the mold to fill the gap between multiple wear-resistant bodies;

[0010] S5, after cooling, forms a wear-resistant ball composed of a cast body and multiple wear-resistant materials.

[0011] Furthermore, the prefabricated wear-resistant body adopts at least one of a columnar structure or a conical structure. The conical structure includes a conical structure and / or a frustum structure. One end face of the columnar structure is planar or partially spherical, and the thick end face of the conical structure is planar or partially spherical.

[0012] Furthermore, the wear-resistant body includes several hexagonal pyramidal structures and several pentagonal pyramidal structures.

[0013] Furthermore, the hexagonal pyramidal structure includes several regular hexagonal frustums or regular hexagonal pyramids, and the pentagonal pyramidal structure includes several regular pentagonal frustums or regular pentagonal pyramids.

[0014] Furthermore, the total number of hexagonal pyramidal structures and pentagonal pyramidal structures is thirty-two, of which there are twelve pentagonal pyramidal structures and twenty hexagonal pyramidal structures; each hexagonal pyramidal structure is adjacent to three pentagonal pyramidal structures and three hexagonal pyramidal structures, and the three pentagonal pyramidal structures and three hexagonal pyramidal structures are arranged alternately; each pentagonal pyramidal structure is adjacent to five hexagonal pyramidal structures.

[0015] Furthermore, the side length of the thick end of the pentagonal pyramid structure is equal to the side length of the thick end of the hexagonal pyramid structure.

[0016] Furthermore, the casting mold is a sand casting mold or a metal casting mold, including a moving mold and a fixed mold. At least one hemispherical mold cavity is respectively opened at the relative position of the parting surface of the moving mold and the fixed mold. The moving mold and the fixed mold are engaged to form at least one of the spherical mold cavities. The pouring channel is opened on at least one of the moving mold and the fixed mold.

[0017] A positioning component for positioning multiple wear-resistant bodies is provided inside the spherical mold cavity. Each positioning area of ​​the positioning component matches a wear-resistant body, fixing multiple wear-resistant bodies radially spaced around the center of the spherical mold cavity, so that one end of each wear-resistant body faces the center of the spherical mold cavity.

[0018] Furthermore, the positioning component includes a mold core, which is spherical in shape and has an outer diameter smaller than the diameter of the spherical surface of the mold cavity. Multiple insertion holes for fixing wear-resistant bodies are radially spaced around the center of the mold core and serve as positioning areas.

[0019] The insertion hole is at least one of a cylindrical hole structure and a conical hole structure. The conical hole structure includes a conical hole structure and / or a frustum-shaped hole structure. Each wear-resistant body is fixedly inserted into one insertion hole.

[0020] Furthermore, the insertion hole includes several hexagonal pyramidal hole structures and several pentagonal pyramidal hole structures.

[0021] Furthermore, the hexagonal pyramidal hole structure includes several regular hexagonal frustum holes or regular hexagonal pyramidal holes, and the pentagonal pyramidal hole structure includes several regular pentagonal frustum holes or regular pentagonal pyramidal holes.

[0022] Furthermore, the total number of hexagonal pyramidal pore structures and pentagonal pyramidal pore structures is thirty-two, of which twenty are hexagonal pyramidal pore structures and twelve are pentagonal pyramidal pore structures; each hexagonal pyramidal pore structure is adjacent to three pentagonal pyramidal pore structures and three hexagonal pyramidal pore structures, and the three pentagonal pyramidal pore structures and three hexagonal pyramidal pore structures are arranged alternately; each pentagonal pyramidal pore structure is adjacent to five hexagonal pyramidal pore structures.

[0023] Each wear-resistant body is fixedly inserted into a pentagonal pyramidal hole structure or a hexagonal pyramidal hole structure.

[0024] Furthermore, the positioning component includes positioning marks spaced apart on the spherical surface of the spherical cavity and around the center of the spherical cavity, for marking each positioning area;

[0025] The positioning marks include at least one of several arc-shaped marks and polygonal marks, and one end face of each wear-resistant body away from the center of the spherical mold cavity is fixed on a positioning mark.

[0026] Furthermore, the positioning marks include a number of regular hexagonal marks and a number of regular pentagonal marks.

[0027] Furthermore, the total number of regular hexagonal and regular pentagonal markers is thirty-two, of which there are twelve regular pentagonal markers and twenty regular hexagonal markers; each regular hexagonal marker is adjacent to three regular pentagonal and regular hexagonal markers, and the three regular pentagonal and regular hexagonal markers are arranged alternately; each regular pentagonal marker is adjacent to five regular hexagonal markers.

[0028] Each wear-resistant body has one end face away from the center of the spherical mold cavity that is matched and attached to a regular pentagonal or regular hexagonal mark and fixed by adhesive.

[0029] Furthermore, the wear resistance of the wear-resistant body is greater than that of the cast body, and the melting point of the wear-resistant body is higher than that of the cast body.

[0030] Furthermore, the first wear-resistant material is made of wear-resistant ceramic material, and the second metal wear-resistant material is cast iron, alloy cast iron, or ductile iron.

[0031] Furthermore, the wear-resistant ceramic material includes at least one of alumina, silicon carbide, silicon nitride, titanium carbide, zirconium oxide, and tungsten carbide.

[0032] Furthermore, the manufacturing method of the wear-resistant ball also includes a process of surface treatment of the wear-resistant ball in S5. The surface treatment process includes, but is not limited to: using a cutting machine to cut off the excess part of the surface of the wear-resistant ball blank, and polishing the surface of the wear-resistant ball blank to improve its surface smoothness.

[0033] On the other hand, the present invention provides a wear-resistant ball, comprising a wear-resistant body and a casting body, wherein a plurality of the wear-resistant bodies are radially spaced around the center of the ball, and the gaps between the plurality of wear-resistant bodies are formed by casting the casting body with a metal material, and the casting body and the plurality of wear-resistant bodies are combined to form a ball.

[0034] Furthermore, one end of each wear-resistant element faces the center of the sphere, while the other end is away from the center of the sphere. The end away from the center of the sphere is either a plane or a sphere, and it is close to the sphere or is part of the sphere.

[0035] Furthermore, the plurality of wear-resistant bodies include at least one of a columnar structure or a conical structure, wherein the conical structure includes a conical structure and / or a frustum-shaped structure.

[0036] Furthermore, the wear-resistant body includes several hexagonal pyramidal structures and several pentagonal pyramidal structures, with the ends of the hexagonal pyramidal structures and pentagonal pyramidal structures away from the center of the sphere having a planar or partially spherical shape.

[0037] Furthermore, the hexagonal pyramidal structure includes several regular hexagonal frustums or regular hexagonal pyramids, and the pentagonal pyramidal structure includes several regular pentagonal frustums or regular pentagonal pyramids.

[0038] Furthermore, the total number of hexagonal pyramidal structures and pentagonal pyramidal structures is thirty-two, of which there are twelve pentagonal pyramidal structures and twenty hexagonal pyramidal structures; each hexagonal pyramidal structure is adjacent to three pentagonal pyramidal structures and three hexagonal pyramidal structures, and the three pentagonal pyramidal structures and three hexagonal pyramidal structures are arranged alternately; each pentagonal pyramidal structure is adjacent to five hexagonal pyramidal structures.

[0039] Furthermore, the extensions of the side edges and / or vertices of the pentagonal pyramid structure and the hexagonal pyramid structure intersect at the center of the sphere.

[0040] Furthermore, the side length of the end face of the pentagonal pyramid structure away from the center of the sphere is equal to the side length of the end face of the hexagonal pyramid structure away from the center of the sphere.

[0041] Furthermore, the wear-resistant body and the casting body are made of different materials, the wear resistance of the wear-resistant body is higher than that of the casting body, and the melting point of the wear-resistant body is higher than that of the casting body.

[0042] Furthermore, the wear-resistant body is made of wear-resistant ceramic material, and the casting body is cast from alloy cast iron or ductile iron material.

[0043] Furthermore, the wear-resistant ceramic material includes at least one of alumina, silicon carbide, silicon nitride, titanium carbide, and zirconium oxide.

[0044] The wear-resistant balls manufactured by the method of this invention have the following beneficial effects: multiple wear-resistant bodies are radially spaced along the radial direction of the wear-resistant ball, and the wear resistance of the wear-resistant bodies is greater than that of the cast body. This not only improves the hardness of the surface layer of the wear-resistant ball but also the hardness of the deeper layers, thus improving the overall wear resistance of the wear-resistant ball. Furthermore, the overall wear resistance of the wear-resistant ball can be controlled by using wear-resistant bodies of different volumes. During the use of the wear-resistant ball, as the surface layer gradually wears down, the wear-resistant bodies arranged along the radial direction of the wear-resistant ball maintain high wear resistance, which improves grinding efficiency, reduces energy consumption, extends the replacement cycle of the wear-resistant ball, and reduces production costs. Attached Figure Description

[0045] Appendix Figure 1 This is a schematic diagram of the structure of the regular pentagonal pyramid 1 in this invention;

[0046] Appendix Figure 2 This is a schematic diagram of the structure of the regular hexagonal pyramid 2 in this invention;

[0047] Appendix Figure 3 This is a cross-sectional structural diagram of the first type of casting mold in this invention. It should be noted that the purpose of using a cross-sectional structural diagram is to more clearly show the structure and position of each component.

[0048] Appendix Figure 4 This is a schematic diagram of the structure of the mold core 6 in this invention;

[0049] Appendix Figure 5 This is a schematic diagram of the structure of the regular pentagonal pyramid 1 and the regular hexagonal pyramid 2 installed behind the mold core 6 in this invention;

[0050] Appendix Figure 6 This is a cross-sectional structural diagram of the second type of casting mold in this invention. It should be noted that the purpose of using the cross-sectional structural diagram is to more clearly show the structure and position of each component. It shows a regular pentagonal pyramid 1 and a regular hexagonal pyramid 2 fixed on the corresponding positioning marks.

[0051] Appendix Figure 7 This is a schematic diagram of the structure of a finished wear-resistant ball manufactured by the wear-resistant ball manufacturing method of the present invention;

[0052] The reference numerals in the attached drawings are explained as follows: 1. Regular pentagonal pyramid frustum; 11. First end face; 2. Regular hexagonal pyramid frustum; 12. Second end face; 3. Casting body; 4. Moving mold; 41. Hemispherical mold cavity; 41. Regular pentagonal mark; 411. Regular hexagonal mark; 412. Gating channel; 42. Fixed mold; 5. Mold core; 6. Regular pentagonal pyramid frustum hole; 61. Regular hexagonal pyramid frustum hole; 62. Detailed Implementation

[0053] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. The invention will be further described below in conjunction with the drawings:

[0054] Example 1

[0055] In this embodiment, the wear-resistant body is described as including twelve regular pentagonal frustums 1 and twenty regular hexagonal frustums 2.

[0056] A method for manufacturing a wear-resistant ball, comprising:

[0057] S1, using wear-resistant ceramic material to prefabricate the wear-resistant body; see attached... Figure 1 , 2 The wear-resistant body includes twelve regular pentagonal pyramidal frustums 1 and twenty regular hexagonal pyramidal frustums 2; the end face of the thick end of the regular pentagonal pyramidal frustum 1 is the first end face 11, and the end face of the thick end of the regular hexagonal pyramidal frustum 2 is the second end face 12. The first end face 11 and the second end face 12 are planes or partially spherical surfaces.

[0058] S2, Construct sand casting molds or metal casting molds; refer to the appendix. Figure 3 The mold includes a moving mold 4, a fixed mold 5 and a mold core 6. At least one hemispherical mold cavity 41 is provided at the relative positions of the bottom surface of the moving mold 4 and the top surface of the fixed mold 5. The moving mold 4 and the fixed mold 5 are fastened to each other to form at least one spherical mold cavity. The pouring channel 42 is provided on the top surface of the moving mold 4 and its bottom end is connected to the spherical mold cavity.

[0059] See attached document Figure 4 The mold core 6 is spherical, and its outer diameter is smaller than the diameter of the spherical surface of the mold cavity. Multiple insertion holes for fixing wear-resistant bodies are radially spaced around the center of the mold core 6 on the surface of the mold core 6, with the inner end of the insertion hole facing the center of the mold core 6. The insertion holes include twenty regular hexagonal frustum holes 62 and twelve regular pentagonal frustum holes 61. Each regular hexagonal frustum hole 62 is adjacent to three regular pentagonal frustum holes 61 and three regular hexagonal frustum holes 62. The three regular pentagonal frustum holes 61 and three regular hexagonal frustum holes 62 are arranged alternately, and each regular pentagonal frustum hole 61 is adjacent to five regular hexagonal frustum holes 62.

[0060] S3, see appendix Figure 5 Twenty regular hexagonal pyramids 2 are fixedly inserted into the twenty regular hexagonal pyramid holes 62, and twelve regular pentagonal pyramids 1 are fixedly inserted into the twelve regular pentagonal pyramid holes 61. The mold core 6, which is filled with regular pentagonal pyramids 1 and regular hexagonal pyramids 2, is placed into the spherical mold cavity, and the first end face 11 and the second end face 12 are close to or attached to the spherical surface of the spherical mold cavity.

[0061] S4, liquid cast iron, alloy cast iron or ductile iron material is poured into the spherical mold cavity through the pouring channel 42 of the mold to fill the gap between the regular pentagonal pyramid 1 and the regular hexagonal pyramid 2, and between the regular hexagonal pyramid 2 and the regular hexagonal pyramid 2.

[0062] S5, a casting 3 formed by cooling liquid cast iron, alloy cast iron, or ductile iron material, is combined with multiple regular pentagonal frustums 1, regular hexagonal frustums 2, and a mold core 6 to form a wear-resistant ball blank. After demolding, the wear-resistant ball blank undergoes surface treatment to obtain the finished wear-resistant ball. Its structure is shown in the attached figure. Figure 7 .

[0063] In step S1, the side length of the thick end of the prefabricated regular pentagonal pyramid 1 is equal to the side length of the thick end of the regular hexagonal pyramid 2. When the adjacent sides of the regular pentagonal pyramid 1 and the regular hexagonal pyramid 2, and the regular hexagonal pyramid 2 and the regular hexagonal pyramid 1 are matched and fitted together, twenty regular hexagonal pyramids 2 and twelve regular pentagonal pyramids 1 can be assembled into a hollow sphere. This is the largest size of the regular pentagonal pyramids 1 and 2. However, there is a lack of a composite connecting structure between the regular pentagonal pyramids 1 and 2, preventing the twenty regular hexagonal pyramids 2 and the twelve regular pentagonal pyramids 1 from forming a single unit. Therefore, in this patent, [the following is omitted as the original text is incomplete and requires further context]. Theoretically, the twenty regular hexagonal frustums 2, which can be completely assembled into a sphere, are proportionally reduced to the twelve regular pentagonal frustums 1. When the twenty regular hexagonal frustums 2 are fixedly inserted into the twenty regular hexagonal frustum holes 62, and the twelve regular pentagonal frustums 1 are fixedly inserted into the twelve regular pentagonal frustum holes 61, gaps are formed between the regular pentagonal frustums 1 and the regular hexagonal frustums 2, and between the regular hexagonal frustums 2 and the regular hexagonal frustums 2. The gaps are filled by casting with metal material to form a casting body 3. The casting body 3, the mold core 6, the twenty regular hexagonal frustums 2 and the twelve regular pentagonal frustums 1 are combined to form a sphere.

[0064] Meanwhile, in order to meet different volume ratios of the casting body and the wear-resistant body in the sphere, twenty regular hexagonal frustums 2 and twelve regular pentagonal frustums 1 can be reduced or enlarged in different proportions. That is, by selecting regular hexagonal frustums 2 and regular pentagonal frustums 1 of different specifications, the area ratio of the wear-resistant body 1 on the surface of the wear-resistant ball will be different. This can be used to control the overall wear resistance of the wear-resistant ball, so as to balance between wear resistance and brittleness, and produce wear-resistant balls with different wear resistance specifications for consumers to choose from.

[0065] In step S2, if a sand casting mold is used, it can be manufactured using 3D printing or a core-shooting machine. Specifically, the 3D printing process is as follows: a sand spreader first evenly spreads a layer of sand (quartz sand), and tens of thousands of 5-micron nozzles are sprayed. Under computer control, resin is sprayed according to the cross-sectional shape of the mold. The resin reacts with the quartz sand to solidify, forming a solidified shape that outlines the cross-section of the mold. After each layer is printed, the lifting platform lowers one layer, and then the layers are stacked one by one. The sand spreader spreads sand, and the printing nozzle sprays resin, alternating between the two processes. After stacking the target layers, the 3D printing of the mold is completed. Finally, a sand blowing process is performed to blow away the uncured quartz sand, and the solidified mold gradually emerges. Sand mold 3D printing is a mature technology and will not be described in detail here.

[0066] The working principle of a core shooter is to inject a core sand mixture with liquid or solid thermosetting resin as a binder into a heated core box (the core box is a process equipment for making core sand into a core; the core here refers to a sand casting mold). The sand core is preheated in the core box and quickly hardens to a certain thickness (about 5 to 10 mm).

[0067] If metal casting molds are used, they can be manufactured through milling or CNC machining. Milling is a machining process where metal material is removed from the workpiece by contacting a rotating cutting tool on a machine tool. When milling metal molds, attention must be paid to the material and wear resistance of the cutting tool to ensure the machining accuracy and quality of the mold surface. CNC machining is a method of manufacturing parts using computer-controlled machine tools. By controlling the movement trajectory of the machine tool and the movement state of the cutting tool through a program, CNC machining can manufacture various complex molds while ensuring machining accuracy and quality. Metal casting molds are also a mature technology and will not be discussed in detail here.

[0068] The plane where the moving mold 4 and the fixed mold 5 interlock is the parting surface. When there is only one hemispherical cavity 41 on the parting surface of the moving mold 4 and the fixed mold 5, the pouring channel 42 is opened on the top surface of the moving mold 4, directly above the hemispherical cavity 41, and its bottom end is connected to the spherical cavity. The bottom end of the pouring channel 42 is located in the gap between the regular hexagonal pyramid 2 and the regular pentagonal pyramid 1 or between the regular hexagonal pyramid 2 and the regular hexagonal pyramid 2, so that the molten steel of cast iron, alloy cast iron or ductile iron material can enter the gap for casting.

[0069] When there are two or more hemispherical cavities 41 opened on the parting surfaces of the moving mold 4 and the fixed mold 5, the pouring channel 42 is opened on the top surface of the moving mold 4, located at the center of the two or more hemispherical cavities 41. The two or more hemispherical cavities 41 surround the circumference with the pouring channel 42 as the center. The bottom end of the channel is connected to each spherical cavity through a transverse flow channel. The other end of the transverse flow channel is located in the gap between the regular hexagonal pyramid 2 and the regular pentagonal pyramid 1 or between the regular hexagonal pyramid 2 and the regular hexagonal pyramid 2, so that molten steel of cast iron, alloy cast iron or ductile iron material can enter the gap for casting.

[0070] In step S3, each regular hexagonal pyramid hole 62 is adjacent to three regular pentagonal pyramid holes 61 and three regular hexagonal pyramid holes 62. The three regular pentagonal pyramid holes 61 and three regular hexagonal pyramid holes are arranged alternately, that is, the three regular pentagonal pyramid holes 61 and three regular hexagonal pyramid holes 62 are arranged alternately around each regular hexagonal pyramid hole 62. There is a gap of one regular hexagonal pyramid hole 62 between two regular pentagonal pyramid holes 61 and a gap of one regular pentagonal pyramid hole 61 between two regular hexagonal pyramid holes 62. Each regular pentagonal pyramid hole 61 is adjacent to five regular hexagonal pyramid holes 62.

[0071] The extensions of the side edges of the regular hexagonal pyramid hole 62 and the regular pentagonal pyramid hole 61 intersect at the center of the mold core 6, so that the twenty regular hexagonal pyramid holes 62 and the twelve regular pentagonal pyramid holes 61 are radially spaced around the center of the mold core 6. The number and distribution of the twenty regular hexagonal pyramid holes 62 and the twelve regular pentagonal pyramid holes 61 are similar to the composition of a soccer ball, which consists of twenty regular hexagons and twelve regular hexagons, and the corresponding distribution.

[0072] Meanwhile, in order to stably fix the regular pentagonal pyramid 1 and the regular hexagonal pyramid 2 in the regular pentagonal pyramid hole 61 and the regular hexagonal pyramid hole 62 of the mold core 6, an adhesive can be applied to the sides of the regular pentagonal pyramid 1 and the regular hexagonal pyramid 2 and / or the sides of the regular pentagonal pyramid hole 61 and the regular hexagonal pyramid hole 62.

[0073] In steps S4 and S5, when a sand casting mold is used, the temperature of the molten steel (liquid cast iron, alloy cast iron, or ductile cast iron) is approximately 1500-1600℃. After pouring, the casting body 3 is cooled and solidified before the moving mold 4 and the fixed mold 5 are separated for demolding. When a metal casting mold is used, the temperature of the molten steel (liquid cast iron, alloy cast iron, or ductile cast iron) is approximately 1500-1600℃. After pouring, the casting body 3 is cooled and solidified before the moving mold 4 and the fixed mold 5 are separated for demolding.

[0074] In step S5, the surface treatment includes: using a cutting machine to cut off the excess part of the surface of the wear-resistant ball blank, including the solidified molten steel remaining in the pouring channel 42 and / or the transverse flow channel, and grinding the surface of the wear-resistant ball blank to improve its surface finish.

[0075] The wear-resistant body has a greater wear resistance than the casting body 3, and the melting point of the wear-resistant body is greater than that of the casting body 3. The melting point of the mold core 6 is greater than or equal to that of the casting body 3, so that the wear-resistant body and the mold core 6 will not be melted by the molten steel during casting. Specifically, the wear-resistant body is made of wear-resistant ceramic material, which includes at least one of alumina, silicon carbide, silicon nitride, titanium carbide, zirconium oxide, and tungsten carbide, with silicon carbide being preferred. The casting body 3 is cast from alloy cast iron or ductile iron.

[0076] Silicon carbide has a hardness second only to diamond and strong wear resistance. Its wear resistance is 5-20 times that of cast iron, and its unit volume cost is also lower, making it a high-performance wear-resistant material. However, silicon carbide has the disadvantages of being brittle and lacking toughness, making it prone to breakage, especially when subjected to impact.

[0077] Currently, it is difficult to directly apply wear-resistant materials such as silicon carbide ceramics to impact-prone environments like wear-resistant balls, as they are likely to crack or break during use. Therefore, this patent proposes a wear-resistant ball composed of a casting body 3 made of alloy cast iron or ductile iron and a wear-resistant body made of multiple wear-resistant ceramic materials. On the one hand, the casting body 3 has strong impact resistance, and on the other hand, it disperses the wear-resistant body and encapsulates it, increasing the impact resistance of the individual silicon carbide. This allows for the application of wear-resistant materials such as silicon carbide ceramics to impact-prone environments like wear-resistant balls without increasing production costs, while significantly improving wear resistance, grinding efficiency, reducing energy consumption, and extending the replacement cycle of wear-resistant balls.

[0078] Under actual operating conditions, as the surface of the wear-resistant ball is gradually worn, the twenty regular hexagonal frustums 2 and twelve regular pentagonal frustums 1 arranged radially can maintain high wear resistance, resulting in good overall wear resistance of the wear-resistant ball. At the same time, considering that under actual operating conditions, the wear-resistant ball with severe wear will reduce its diameter and affect the grinding efficiency, if the diameter of the wear-resistant ball decreases by 50% to 90% after wear, that is, the diameter of the remaining part of the wear-resistant ball after wear is 10% to 50% (minimum 10% to 20%) of the initial diameter of the wear-resistant ball, then replacement needs to be considered. Therefore, the length of the regular hexagonal frustums 2 and regular pentagonal frustums 1 is designed to be 50% to 90% of the radius of the wear-resistant ball.

[0079] Example 2

[0080] In this embodiment, the wear-resistant body is also described using the example of twelve regular pentagonal pyramidal frustums 1 and twenty regular hexagonal pyramidal frustums 2.

[0081] A method for manufacturing a wear-resistant ball, comprising:

[0082] S1, using wear-resistant ceramic material to prefabricate the wear-resistant body; see attached... Figure 1 ,2 The wear-resistant body includes twelve regular pentagonal pyramidal frustums 1 and twenty regular hexagonal pyramidal frustums 2; the end face of the thick end of the regular pentagonal pyramidal frustum 1 is the first end face 11, and the end face of the thick end of the regular hexagonal pyramidal frustum 2 is the second end face 12. The first end face 11 and the second end face 12 are planes or partially spherical surfaces.

[0083] S2, Construct the sand casting mold; refer to the appendix. Figure 6 The mold includes a moving mold 4 and a fixed mold 5. At least one hemispherical cavity 41 is provided at the relative position of the bottom surface of the moving mold 4 and the top surface of the fixed mold 5. The moving mold 4 and the fixed mold 5 are fastened to each other to form at least one spherical cavity. The pouring channel 42 is provided on the top surface of the moving mold 4, and its bottom end is connected to the spherical cavity.

[0084] Twenty regular hexagonal marks 412 and twelve regular pentagonal marks 411 are distributed at intervals on the spherical surface of the spherical cavity and around the center of the spherical cavity. Each regular hexagonal mark 412 is adjacent to three regular pentagonal marks 411 and three regular hexagonal marks 412. The three regular pentagonal marks 411 and three regular hexagonal marks 412 are arranged alternately, that is, the three regular pentagonal marks 411 and three regular hexagonal marks 412 around each regular hexagonal mark 412 are arranged alternately. There is a gap of one regular hexagonal mark 412 between two regular pentagonal marks 411 and a gap of one regular pentagonal mark 411 between two regular hexagonal pyramids 12. Each regular pentagonal mark 411 is adjacent to five regular hexagonal marks 412.

[0085] S3, the second end face 12 of a regular hexagonal pyramid 2 is matched and attached to a regular hexagonal mark 412 and fixed with adhesive. The first end face 11 of a regular pentagonal pyramid 1 is matched and attached to a regular pentagonal mark 411 and fixed with adhesive. Twelve regular pentagonal pyramids 1 and twenty regular hexagonal pyramids 2 are respectively bonded and fixed to twelve regular pentagonal marks 411 and twenty regular hexagonal marks 412 using the above method. Since the prepared material is a wear-resistant ball, it is formed by combining two hemispherical molds. The position of some wear-resistant elements may be located at the junction of the two hemispherical molds. For wear-resistant elements at this position, during fixing, they are fixed to one of the two hemispherical molds, preferably to the one with a relatively larger surface area.

[0086] S4, liquid alloy cast iron or ductile iron material is poured into the spherical mold cavity through the pouring channel 42 of the mold to fill the gaps between the regular pentagonal pyramid 1 and the regular hexagonal pyramid 2, between the regular hexagonal pyramid 2 and the spherical mold cavity center.

[0087] S5, a casting 3 formed by cooling liquid alloy cast iron or ductile iron material, is combined with multiple regular pentagonal frustums 1 and regular hexagonal frustums 2 to form a wear-resistant ball blank. After demolding, the wear-resistant ball blank undergoes surface treatment to obtain the finished wear-resistant ball. The first end face 11 and the second end face 12 form part of the surface of the wear-resistant ball. The structure of the wear-resistant ball is shown in the attached figure. Figure 7 .

[0088] In step S1, when the side length of the thick end of the prefabricated regular pentagonal pyramid 1 is equal to the side length of the thick end of the regular hexagonal pyramid 2, and when the adjacent sides of the regular pentagonal pyramid 1 and the regular hexagonal pyramid 2, and the regular hexagonal pyramid 2 and the regular hexagonal pyramid 1 are matched and fitted together, twenty regular hexagonal pyramids 2 and twelve regular pentagonal pyramids 1 can be assembled into a hollow sphere. This is the largest size of the regular pentagonal pyramids 1 and 2. However, there is a lack of composite connecting structure between the regular pentagonal pyramids 1 and 2, so the twenty regular hexagonal pyramids 2 and the twelve regular pentagonal pyramids 1 cannot form a whole. Therefore, in this patent... Theoretically, the largest possible size of twenty regular hexagonal frustums 2 that can be completely assembled into a sphere is proportionally reduced to twelve regular pentagonal frustums 1. When the twenty regular hexagonal frustums 2 are respectively fixedly inserted into the twenty regular hexagonal frustum holes 62, and the twelve regular pentagonal frustums 1 are respectively fixedly inserted into the twelve regular pentagonal frustum holes 61, gaps are formed between the regular pentagonal frustums 1 and the regular hexagonal frustums 2, and between the regular hexagonal frustums 2 and the regular hexagonal frustums 2. The gaps are filled by casting metal material to form a casting body 3. The casting body 3, the twenty regular hexagonal frustums 2, and the twelve regular pentagonal frustums 1 are combined to form a sphere.

[0089] Meanwhile, in order to meet different volume ratios of the casting body and the wear-resistant body in the sphere, twenty regular hexagonal frustums 2 and twelve regular pentagonal frustums 1 can be reduced or enlarged in different proportions. That is, by selecting regular hexagonal frustums 2 and regular pentagonal frustums 1 of different specifications, the area ratio of the wear-resistant body 1 on the surface of the wear-resistant ball will be different. This can be used to control the overall wear resistance of the wear-resistant ball, so as to balance between wear resistance and brittleness, and produce wear-resistant balls with different wear resistance specifications for consumers to choose from.

[0090] In step S2, if a sand casting mold is used, it can be manufactured using 3D printing or a core-shooting machine. Specifically, the 3D printing process is as follows: a sand spreader first evenly spreads a layer of sand (quartz sand), and tens of thousands of 5-micron nozzles are sprayed. Under computer control, resin is sprayed according to the cross-sectional shape of the mold. The resin reacts with the quartz sand to solidify, forming a solidified shape that outlines the cross-section of the mold. After each layer is printed, the lifting platform lowers one layer, and then the layers are stacked one by one. The sand spreader spreads sand, and the printing nozzle sprays resin, alternating between the two processes. After stacking the target layers, the 3D printing of the mold is completed. Finally, a sand blowing process is performed to blow away the uncured quartz sand, and the solidified mold gradually emerges. Sand mold 3D printing is a mature technology and will not be described in detail here.

[0091] The working principle of a core shooter is to inject a core sand mixture, using liquid or solid thermosetting resin as a binder, into a heated core box (the core box is the process equipment for forming the core sand into a mold; here, the mold refers to the sand casting mold). The sand core is preheated and quickly hardens to a certain thickness (approximately 5-10 mm) within the core box. To fix the wear-resistant material to the inner surface of the sand mold, it can be bonded using a high-temperature resistant adhesive.

[0092] When there is only one hemispherical cavity 41 opened at the relative position of the parting surface of the moving mold 4 and the fixed mold 5, the pouring channel 42 is opened on the top surface of the moving mold 4, directly above the hemispherical cavity 41, and its bottom end is connected to the spherical cavity. The bottom end of the pouring channel 42 is located in the gap between the regular hexagonal pyramid 2 and the regular pentagonal pyramid 1 or between the regular hexagonal pyramid 2 and the regular hexagonal pyramid 2; so that molten steel of cast iron, alloy cast iron or ductile iron material can enter the gap for casting.

[0093] When there are two or more hemispherical cavities 41 respectively opened at the relative positions of the parting surfaces of the moving mold 4 and the fixed mold 5, the pouring channel 42 is opened on the top surface of the moving mold 4, located at the center of the two or more hemispherical cavities 41. The two or more hemispherical cavities 41 surround the circumference with the pouring channel 42 as the center. The bottom end of the channel is connected to each spherical cavity through a transverse flow channel. The other end of the transverse flow channel is located in the gap between the regular hexagonal frustum 2 and the regular pentagonal frustum 1 or between the regular hexagonal frustum 2 and the regular hexagonal frustum 2. This facilitates the entry of molten steel of cast iron, alloy cast iron or ductile iron into the gap for casting.

[0094] In step S2, the regular hexagonal mark 412 and the regular pentagonal mark 411 can be printed together when 3D printing the sand casting mold. Specifically, the regular hexagonal mark 412 and the regular pentagonal mark 411 are local spherical grooves or local spherical protrusions that match the dimensions of the second end face 12 and the first end face 11, or regular hexagonal line grooves, regular pentagonal line grooves or regular hexagonal line protrusions or regular pentagonal line protrusions that match the edges of the second end face 12 and the first end face 11. During installation, it is only necessary to match and align the second end face 12 and the first end face 11 with the above-mentioned grooves or protrusions, and then fix them with adhesive.

[0095] Since the precision of 3D printed sand casting molds can reach 0.3mm, the above-mentioned grooves or protrusions can be designed with a depth or thickness of 0.3mm-0.5mm, preferably a protrusion thickness of 0.3mm-0.5mm.

[0096] After casting, the wear-resistant ball blank will have a step between the wear-resistant body and the casting body 3. That is, the wear-resistant body is concave to the casting body 3 by 0.3mm-0.5mm. However, the wear-resistant ball blank will be surface-polished during surface treatment. Therefore, the casting body 3 can be polished away by 0.3mm-0.5mm to eliminate the step between the wear-resistant body and the casting body 3.

[0097] In step S3, the adhesive used is a sand-type adhesive or an inorganic high-temperature adhesive. The high-temperature adhesive has excellent high-temperature resistance and corrosion resistance, and can withstand high temperatures of up to about 1800℃, ensuring that the bonding and fixing effect is maintained during the casting of molten steel, and preventing the regular hexagonal pyramid 2 and the regular pentagonal pyramid 1 from falling off before the molten steel cools and solidifies.

[0098] After the twelve regular pentagonal frustums 1 and the twenty regular hexagonal frustums 2 are respectively bonded and fixed to the twelve regular pentagonal marks 411 and the twenty regular hexagonal marks 412 using the above method, the extension lines of each side edge of the regular hexagonal frustums 2 and the regular pentagonal frustums 1 intersect at the center of the spherical mold cavity, so that the twenty regular hexagonal frustums 2 and the twelve regular pentagonal frustums 2 are radially spaced around the center of the spherical mold cavity, and each regular hexagonal frustum 2 is adjacent to three regular pentagonal frustums 1, and the three regular hexagonal frustums 2, the three regular pentagonal frustums 1 and the three regular hexagonal frustums 2 are arranged alternately, that is, the three regular pentagonal frustums 1 and the three regular hexagonal frustums 2 are arranged alternately around each regular hexagonal frustum 2, and there is a gap of one regular hexagonal frustum 2 between two regular pentagonal frustums 1 and a gap of one regular pentagonal frustum 1 between two regular hexagonal frustums 2; each regular pentagonal frustum 1 is adjacent to five regular hexagonal frustums 2.

[0099] In steps S4 and S5, the temperature of the molten steel material (liquid cast iron, alloy cast iron, or ductile iron) is about 1500-1600℃. After the casting is completed, the moving mold 4 and the fixed mold 5 are separated and the casting is removed after the casting body 3 has cooled and solidified.

[0100] The specific demolding method is as follows: use equipment to separate the moving mold 4 and the fixed mold 5, or break the sand casting mold as a whole to remove the wear-resistant ball blank.

[0101] In step S5, the surface treatment includes: using a cutting machine to cut off the excess part of the surface of the wear-resistant ball blank, including the solidified molten steel remaining in the pouring channel 42 and / or the transverse flow channel, and grinding the surface of the wear-resistant ball blank to improve its surface finish.

[0102] The wear-resistant body has greater wear resistance than the casting 3, and its melting point is higher than that of the casting 3, preventing it from melting in the molten steel during casting. Specifically, the wear-resistant body is made of wear-resistant ceramic material, including at least one of alumina, silicon carbide, silicon nitride, titanium carbide, zirconium oxide, and tungsten carbide, with silicon carbide being preferred. The casting 3 is cast from cast iron, alloy cast iron, or ductile iron. Preferably, the wear-resistant body and the casting 3 are made of materials that do not react with each other. In a preferred embodiment, the surface of the wear-resistant body has a protective film. Preferably, the protective film is formed by coating hard alloy powder with a light- or thermosetting adhesive.

[0103] Silicon carbide has a hardness second only to diamond and strong wear resistance. Its wear resistance is 5-20 times that of cast iron, and its unit volume cost is also lower, making it a high-performance wear-resistant material. However, silicon carbide has the disadvantages of being brittle and lacking toughness, making it prone to breakage, especially when subjected to impact.

[0104] Currently, it is difficult to directly apply wear-resistant materials such as silicon carbide ceramics to impact-prone environments like wear-resistant balls, as they are likely to crack or break during use. Therefore, this patent proposes a wear-resistant ball composed of a casting body 3 made of alloy cast iron or ductile iron and a wear-resistant body made of multiple wear-resistant ceramic materials. On the one hand, the casting body 3 has strong impact resistance, and on the other hand, it disperses the wear-resistant body and encapsulates it, increasing the impact resistance of the individual silicon carbide. This allows for the application of wear-resistant materials such as silicon carbide ceramics to impact-prone environments like wear-resistant balls without increasing production costs, while significantly improving wear resistance, grinding efficiency, reducing energy consumption, and extending the replacement cycle of wear-resistant balls.

[0105] Under actual operating conditions, as the surface of the wear-resistant ball is gradually worn, the twenty regular hexagonal frustums 2 and twelve regular pentagonal frustums 1 arranged radially can maintain high wear resistance, resulting in good overall wear resistance of the wear-resistant ball. At the same time, considering that under actual operating conditions, the wear-resistant ball with severe wear will reduce its diameter and affect the grinding efficiency, if the diameter of the wear-resistant ball decreases by 50% to 90% after wear, that is, the diameter of the remaining part of the wear-resistant ball after wear is 10% to 50% (minimum 10% to 20%) of the initial diameter of the wear-resistant ball, then replacement needs to be considered. Therefore, the length of the regular hexagonal frustums 2 and regular pentagonal frustums 1 is designed to be 50% to 90% of the radius of the wear-resistant ball.

[0106] It is obvious that modifications and / or additions can be made to the above-described wear-resistant balls and corresponding methods without departing from the scope and domain of the present invention.

[0107] It is equally clear that, although the present invention has described the method of manufacturing the wear-resistant ball in detail, those skilled in the art will certainly be able to obtain many other equivalent methods of manufacturing wear-resistant balls, which have the features described in the claims and are therefore within the scope of protection defined herein.

Claims

1. A method for manufacturing a wear-resistant ball, characterized in that: include: S1, prefabricated multiple wear-resistant bodies composed of a first wear-resistant material; S2, make a casting mold, and form at least one spherical cavity and a pouring channel connected to the spherical cavity in the mold; S3, multiple wear-resistant materials are fixed radially and spaced around the center of the spherical mold cavity; S4, the second metal wear-resistant material is poured into the spherical mold cavity through the pouring channel of the mold to fill the gap between multiple wear-resistant bodies; S5, after cooling, forms a wear-resistant ball composed of a cast body and multiple wear-resistant materials.

2. The method for manufacturing wear-resistant balls according to claim 1, characterized in that: The prefabricated wear-resistant body adopts at least one of columnar or conical structures. The conical structure includes a conical structure and / or a frustum structure. One end face of the columnar structure is planar or partially spherical, and the thick end face of the conical structure is planar or partially spherical.

3. The method for manufacturing wear-resistant balls according to claim 2, characterized in that: The wear-resistant body comprises several hexagonal pyramidal structures and several pentagonal pyramidal structures.

4. The method for manufacturing wear-resistant balls according to claim 3, characterized in that: The hexagonal pyramidal structure includes several regular hexagonal frustums (2) or regular hexagonal pyramids, and the pentagonal pyramidal structure includes several regular pentagonal frustums (1) or regular pentagonal pyramids.

5. The method for manufacturing wear-resistant balls according to claim 3, characterized in that: The total number of hexagonal pyramidal structures and pentagonal pyramidal structures is thirty-two, of which there are twelve pentagonal pyramidal structures and twenty hexagonal pyramidal structures; each hexagonal pyramidal structure is adjacent to three pentagonal pyramidal structures and three hexagonal pyramidal structures, and the three pentagonal pyramidal structures and three hexagonal pyramidal structures are arranged alternately; each pentagonal pyramidal structure is adjacent to five hexagonal pyramidal structures.

6. The method for manufacturing wear-resistant balls according to claim 3, characterized in that: The side length of the thick end of the pentagonal pyramid structure is equal to the side length of the thick end of the hexagonal pyramid structure.

7. The method for manufacturing wear-resistant balls according to claim 1, characterized in that: The casting mold is a sand casting mold or a metal casting mold, including a moving mold (4) and a fixed mold (5). At least one hemispherical mold cavity (41) is opened at the relative position of the parting surface of the moving mold (4) and the fixed mold (5). The moving mold (4) and the fixed mold (5) are engaged to form at least one of the spherical mold cavities. The pouring channel (42) is opened on at least one of the moving mold (4) and the fixed mold (5). A positioning component for positioning multiple wear-resistant bodies is provided inside the spherical mold cavity. Each positioning area of ​​the positioning component matches a wear-resistant body, fixing multiple wear-resistant bodies radially spaced around the center of the spherical mold cavity, so that one end of each wear-resistant body faces the center of the spherical mold cavity.

8. The method for manufacturing wear-resistant balls according to claim 7, characterized in that: The positioning component includes a mold core (6), which is spherical and its outer diameter is smaller than the diameter of the spherical surface of the mold cavity. Multiple insertion holes for fixing wear-resistant bodies are radially spaced around the center of the mold core (6) and used as positioning areas. The insertion hole is at least one of a cylindrical hole structure and a conical hole structure. The conical hole structure includes a conical hole structure and / or a frustum-shaped hole structure. Each wear-resistant body is fixedly inserted into one insertion hole.

9. The method for manufacturing wear-resistant balls according to claim 8, characterized in that: The insertion hole includes several hexagonal pyramidal hole structures (62) and several pentagonal pyramidal hole structures (61).

10. The method for manufacturing wear-resistant balls according to claim 9, characterized in that: The hexagonal pyramidal hole structure (62) includes several regular hexagonal pyramidal holes or regular hexagonal pyramidal holes, and the pentagonal pyramidal hole structure (61) includes several regular pentagonal pyramidal holes or regular pentagonal pyramidal holes.

11. The method for manufacturing wear-resistant balls according to claim 9, characterized in that: The total number of hexagonal pyramidal hole structures (62) and pentagonal pyramidal hole structures (61) is thirty-two, of which there are twenty hexagonal pyramidal hole structures (62) and twelve pentagonal pyramidal hole structures (61); each hexagonal pyramidal structure is adjacent to three pentagonal pyramidal hole structures (61) and three hexagonal pyramidal hole structures (62), and the three pentagonal pyramidal hole structures (61) and three hexagonal pyramidal hole structures (62) are arranged alternately; each pentagonal pyramidal hole structure (61) is adjacent to five hexagonal pyramidal hole structures (62); Each wear-resistant body is fixedly inserted into a pentagonal pyramidal hole structure (61) or a hexagonal pyramidal hole structure (62).

12. The method for manufacturing wear-resistant balls according to claim 7, characterized in that: The positioning component includes positioning marks spaced apart on the spherical surface of the spherical cavity and around the center of the spherical cavity, for marking each positioning area; The positioning marks include at least one of arc-shaped marks and polygonal marks, and one end face of each wear-resistant body away from the center of the spherical mold cavity is fixed on a positioning mark.

13. The method for manufacturing wear-resistant balls according to claim 12, characterized in that: The positioning marks include a number of regular hexagonal marks (412) and a number of regular pentagonal marks (411).

14. The method for manufacturing wear-resistant balls according to claim 13, characterized in that: The total number of regular hexagonal markers (412) and regular pentagonal markers (411) is thirty-two, of which there are twelve regular pentagonal markers (411) and twenty regular hexagonal markers (412); each regular hexagonal marker (412) is adjacent to three regular pentagonal markers (411) and regular hexagonal markers (412), and the three regular pentagonal markers (411) and regular hexagonal markers (412) are arranged alternately; each regular pentagonal marker (411) is adjacent to five regular hexagonal markers (412); Each wear-resistant body has one end face away from the center of the spherical mold cavity that is matched and attached to a regular pentagonal mark (411) or a regular hexagonal mark (412) and fixed by an adhesive.

15. The method for manufacturing wear-resistant balls according to claim 1, characterized in that: The wear resistance of the wear-resistant body is greater than that of the cast body (3), and the melting point of the wear-resistant body is higher than that of the cast body (3).

16. The method for manufacturing wear-resistant balls according to claim 1, characterized in that: The first wear-resistant material is made of wear-resistant ceramic material, and the second metal wear-resistant material is cast iron, alloy cast iron or ductile iron.

17. The method for manufacturing wear-resistant balls according to claim 16, characterized in that: The wear-resistant ceramic material includes at least one of alumina, silicon carbide, silicon nitride, titanium carbide, zirconium oxide, and tungsten carbide.

18. The method for manufacturing wear-resistant balls according to claim 1, characterized in that: The manufacturing method of the wear-resistant ball also includes a process of surface treatment of the wear-resistant ball in S5. The surface treatment process includes, but is not limited to: using a cutting machine to cut off the excess part of the surface of the wear-resistant ball blank, and polishing the surface of the wear-resistant ball blank to improve its surface smoothness.

19. A wear-resistant ball, characterized in that: The ball includes a wear-resistant body and a casting body. A plurality of wear-resistant bodies are radially spaced around the center of the ball. The gaps between the wear-resistant bodies are formed by casting metal material to form the casting body. The casting body and the plurality of wear-resistant bodies are combined to form a ball. The wear-resistant ball is manufactured using the method described in any one of claims 1-18.

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