What is the acceptable range for wear of the mill steel rods?

Operating time is certainly not objective; the main purpose of the mill is to produce qualified coal slurry, and the amount of steel rods as well as their distribution should be adjusted to match the operating load. Appropriate steel rods should be added based on the degree of wear of the existing ones, to ensure that qualified coal slurry can be produced over a certain period of time.

Reply to 2# xuqinger: The specifications of the steel rods are 75, 65, and 50. So when should the rods be replaced due to wear?

This post was last edited by GSP on 2011-5-23 at 13:34. Wear-resistant steel rods for rod mills are suitable for a wide range of users and manufacturers of rod mills and coal grinding mills, including cement plants, power plants, mines, quartz sand factories, silica sand factories, sand aeration plants, coal chemical industries, and aerated concrete factories. The steel rods currently in use in the market are produced by steel mills through rolling processes; they require low technical standards, have extremely poor wear resistance, and result in high consumption during use, leading to significant waste of ** resources. 1. Analysis of the broken rod phenomenon: (1) Causes: A. Material: internal porosity. Regarding the issues with steel billets in steel mills, only very large-scale mills are able to meet the stringent technical requirements involved, especially for those with a diameter of over 70 mm. While most steel mills can produce billets of this type, their compression ratio and hardenability are low, meaning that their structure is not dense enough. B. Process: The internal internal stress has not been relieved. Bar breakage is like an explosion, occurring from within; the principle behind steel mills producing steel bars is similar to blowing up a balloon – it is necessary to eliminate the internal stresses in order to prevent bar breakage. (2) Solution: A. Focus on the materials. a. Try to use materials from **super-large steel mills** ； b. The new alloy material developed by our company was specifically created by industry experts in wear resistance from Tsinghua University and Dalian University of Technology, taking into account the conditions under which rod mills operate. It possesses excellent hardenability, and is produced by a **very large steel factory (under a confidential agreement). B. Processing technology: The steel rod processing technology developed by our company has been granted a **patent**; it significantly improves the wear resistance of the steel rods, and breakage does not occur (we will replace them free of charge if they break). C. The size specifications can be adjusted flexibly; generally, the steel bars supplied by steel mills are 6 meters long. If you use 4-meter long bars, then the 2 meters that remain will be wasted. Our company can produce bars to custom lengths. D. The wear-resistant steel rods produced by our company using new materials and processes extend their service life, reduce costs, and lessen the workload on workers. Don’t worry about stopping the mill and adding steel rods every day – it even **increases production**. 2. Regarding the hardness of the steel rod: The optimal hardness level is 45-50. If it is lower than this, the rod is too soft and not wear-resistant; if it is higher, it is too hard and brittle, making it prone to breaking ； Furthermore, in terms of manufacturing processes, domestic manufacturers can only achieve an HRC hardness of over 45 on the surface of the steel rod for a maximum of one centimeter; beyond that one centimeter, the surface becomes identical to that of a round steel bar. The wear-resistant steel rods used in our rod mills are manufactured in accordance with international standards. Moreover, thanks to our proprietary manufacturing process (which has been patented), the overall performance of these steel rods is improved. For example, while ordinary steel rods have a surface hardness of HRC 45 and an internal hardness of HRC 10, our rods can achieve a surface hardness of HRC 50 and an internal hardness of HRC 25. 3. Differences between wear-resistant steel rods, regular steel rods, and round bars: Round bars are raw materials produced by steel mills; they are not finished products. Using them as steel rods in rod mills leads to various problems such as rod breakage and failure (with sharp ends at both ends). Their hardness is only 20, so they are completely not wear-resistant! Steel rods are produced through further processing of round steel; their surface hardness is 45-50, making the surface wear-resistant while the interior is not. Wear-resistant steel rods are the true steel rods for rod mills. 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