Ceramic Ball Material With Belt-Mark Removal for Heavy-Load Durability
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Solution Overview
Problem
Existing ceramic ball materials produced by tumbling granulation have poor durability due to low density and are limited in size, making them unsuitable for applications under heavy loads.
Innovation Solution
A ceramic ball material with a sphericity of 2% or less and an arithmetic mean roughness Ra of 0.2 µm or more and 2 µm or less, produced by sintering a ceramic formed body from which the belt-like portion has been completely removed, enhancing polishing efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tumbling granulation is used to produce ceramic ball material, then polishing efficiency is improved due to absence of belt-like portion, but durability deteriorates due to low density
Solution Approach 1:
The invention changes the pressing pressure parameter from low (tumbling granulation) to high (100-500 MPa), which transforms the formed body density from poor to high density, thereby improving durability while maintaining the absence of belt-like portion for good polishing efficiency
Solution Approach 2:
The invention performs preliminary densification by applying high pressing pressure during formed body production, creating a densely packed green body before sintering. This preliminary action ensures high density is achieved early in the process, preventing the durability problems that would arise from low-density tumbling granulation
2Productivity
If tumbling granulation is used to produce ceramic ball material, then polishing efficiency is improved, but manufacturing precision deteriorates due to size limitations
Solution Approach 1:
The invention changes the pressing pressure parameter to enable production of larger sized formed bodies with controlled dimensions, overcoming the size limitations of tumbling granulation while maintaining good sphericity and surface quality for efficient polishing
3Manufacturing precision
If die pressing is used to produce ceramic formed body, then manufacturing precision is improved, but device complexity increases due to belt-like portion
Solution Approach 1:
The invention extracts and eliminates the belt-like portion from the formed body by optimizing the die pressing process parameters, thereby removing the source of polishing inefficiency while maintaining the manufacturing precision benefits of die pressing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The material achieves improved polishing efficiency and excellent durability, making it suitable for applications under heavy loads, while also reducing the polishing allowance.
Implementation Method 1
a material for a ceramic ball is produced by sintering a ceramic formed body
Data Source
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AI summary
A material for a ceramic ball according to the present embodiment is characterized in that a deviation from spherical form is 2% or less, and an arithmetic mean roughness Ra is 0.2 µm to 2 µm inclusive. Moreover, in the material for a ceramic ball, a maximum cross-sectional height Rt is preferably 4 µm to 20 µm inclusive. Furthermore, in the material for a ceramic ball, Ra1/Ra2 is preferably 0.2 to 2, where Ra1 is the surface roughness Ra in a circumferential direction of a belt-like mark, and Ra2 is the surface roughness Ra of a circumference in a direction perpendicular to the belt-like mark.