Differences Between Forged Grinding Balls and Cast Grinding Balls

At present, the common forming processes for wear-resistant steel balls mainly include casting, forging, and rolling. For large-diameter steel balls, the main production processes are mainly forging and casting. So, what is the difference between forged grinding balls and cast grinding balls? This article will tell you in detail.

Material

Forged grinding balls

The raw materials for forged grinding balls are usually high-quality round steel or high-quality alloy structural steel, with carbon content generally less than 1.4%. Therefore, the forged products are called steel balls. The high purity and uniform metallographic structure of this material make forged grinding balls perform excellently under high impact and high wear conditions.

Cast grinding balls

The raw materials for cast grinding balls are mainly scrap steel. By melting and adding alloy elements such as chromium and manganese, the carbon content reaches 2.2% to 3.5%, manifesting as iron-based composition. After casting and heat treatment, cast grinding balls are more accurately referred to as iron balls. This material is characterized by higher hardness.

Physical Properties

Forged grinding balls

Forged grinding balls have excellent impact toughness, usually greater than 12J/cm², and a breakage rate of less than 1%. This characteristic allows them to exhibit longer service life under high impact and heavy-load conditions.

Cast grinding balls

In comparison, cast grinding balls have lower impact toughness, between 2-6J/cm², and a breakage rate of about 0.5-1%.

Surface Quality

Forged grinding balls

Forged grinding balls are processed using high-precision die-forging technology, resulting in smooth and defect-free surfaces. This surface quality not only enhances the wear resistance of the balls but also reduces local stress concentration caused by surface flaws during use.

Cast grinding balls

Cast grinding balls are molded through sand molds or metal molds, producing relatively smooth surfaces with gating marks.

Application Fields

Forged grinding balls

Forged grinding balls, made from high-quality alloy steel and enhanced by advanced heat treatment processes for corrosion resistance, are suitable for both dry grinding and wet grinding conditions. For example, in mineral processing, semi-autogenous grinding mills, and other heavy-load wet grinding environments, forged grinding balls perform excellently.

Cast grinding balls

Cast grinding balls are more suitable for ball mills or cement mills, where cast balls have a grinding effect that forged balls cannot replace.

Heat Treatment Methods

Forged grinding balls

Forged grinding balls usually undergo water quenching or quenching liquid quenching processes. This treatment method can significantly improve the hardness and toughness of the grinding balls, thereby enhancing their wear resistance.

Cast grinding balls

Cast grinding balls use oil quenching or air quenching processes to improve the hardness and wear resistance of the balls.

In summary, both cast grinding balls and forged grinding balls have their superior performances and should be selected according to the specific mining and milling environment.