Alloy Steel Solutions

Process development process:

Demand Analysis and Material Selection: First, based on the working conditions and usage requirements of the medium-speed coal mill in the power plant, the team analyzed the material properties required for the grinding balls. Since the grinding balls need to be used for a long time in a high-wear environment, alloy steel was selected as the main material, with its high hardness, high toughness and corrosion resistance as its main advantages.

Alloy composition design: Based on the material selection, the engineering team further optimized the alloy composition and added elements such as chromium, molybdenum, and vanadium to improve the wear resistance and thermal stability of the alloy steel. Through experiments and computer simulations, the optimal alloy ratio was determined to ensure that the grinding balls can still maintain good performance under high temperature and high pressure environments.

Production process development: During the development process, the team adopted the lost foam process to shape and fix the internal sand core in a special way to solve the uneven wall thickness of the eccentric core and the appropriate heat treatment process to ensure that the internal structure of the grinding ball is dense and the surface hardness is high and uniform. In particular, in the heat treatment process, the quenching and tempering process route is adopted to further enhance the wear resistance and impact toughness of the grinding ball. In addition, the team also designed a special mold to ensure the dimensional accuracy and surface quality of the grinding ball.

Performance testing and optimization: After completion of manufacturing, the grinding balls passed a number of rigorous performance tests, including wear resistance testing, impact testing, hardness testing and usage testing under simulated actual working conditions. Test results show that the alloy steel grinding ball performs well under high load and has a significantly improved service life. Based on test feedback, the team made fine-tuning to further optimize product performance.

Application and feedback: The final product was successfully applied in the medium-speed coal mill of the power plant, significantly improving the operating efficiency of the equipment and reducing downtime. Feedback from the power plant shows that the new alloy steel grinding ball has a service life of 30% longer than the traditional grinding ball and shows higher efficiency in the coal crushing process.

Results and advantages:

Through precise material design and advanced manufacturing processes, your company has successfully developed a high-performance alloy steel grinding ball for medium-speed coal mills. This product not only meets the strict requirements of power plants for wear resistance and impact resistance, but also helps customers reduce operating costs by extending equipment life and improving operating efficiency. This case demonstrates your company's technical strength and innovation capabilities in high-end industrial applications.