Production Process

 

In the cold heading machine, the wire is cut into short lengths and formed into spherical shapes between dies. The wire is cut to a specific length and then compressed by the dies at room temperature to undergo plastic deformation to form a ball blank.

 

Drawing is the process of pulling the iron wire rod to an exact size to facilitate pressing. The wire is drawn to the required diameter using a wire drawing machine.

 

In the flashing process, the ridge left by the forming dies is removed as balls roll between heavy cast iron plates. The forged steel balls are sandwiched between two hard cast discs and pressure is applied to rotate them, removing burrs and surface rings and improving the surface roughness of the balls to make them initially spherical.

 

 

Heat treatment involves carburizing, quenching, and tempering to enhance the hardness, strength, wear resistance, and contact fatigue resistance of the steel balls. This process also yields comprehensive mechanical properties such as elasticity, toughness, and dimensional stability.

 

 

 

Hard grinding is the process of using a grinding wheel to grind the heat-treated ball blanks under pressure, removing the black oxide layer on the surface and correcting the accuracy of the ball.

 

 

 

 

 

Two cast iron primary grinding discs are used, and abrasive materials are added. The specified precision surface quality is achieved through certain pressure and mechanical movement.

 

 

 

 

 

Similar to the first grinding process, two cast iron lapping plates are used, and abrasives are added to remove excess material under certain pressure and mechanical movement, thereby further improving the precision and surface quality of the steel ball.

 

 

 

The balls are placed in a polishing drum and turned, then washed with polishing detergent and water to make the spherical surface clean and bright. Chemicals mainly comprising magnesium oxide are added to reduce surface roughness, and the polishing process resolves the issue of luster.

 

 

Preliminary screening of steel balls is an essential step in the production process. It preliminarily screens out iron sheets and steel balls smaller than the specified size, simplifying the subsequent screening work.
 

 

 

Specially designed for sorting steel ball defects and dimensional accuracy. It is mainly suitable for ball products and effectively sorts foreign balls, surface defects, scraps, ellipsoids, etc., in ball products.

 

 

 

Manual visual inspection is used to check for any flaws on the surface of the steel ball. A micrometer is used to measure roundness and batch diameter variation, and a surface roughness meter detects surface roughness as the final inspection step.

 

Packing Types

 

A. Steel Drum Packing: Each drum contains 250kg of steel balls, with four drums on one pallet; the pallet size is 75cm x 75cm x 65cm.

B. Plywood Box Packing: Each plywood box contains 40 cartons/woven bags; the plywood box size is 80cm x 65cm x 80cm.

C. Use of a 20ft container is recommended, with a maximum loading capacity of 24 tons.

D. A 20ft container loading of 24 tons totals 24 Plywood Boxes or Drums.