MAIN PRODUCTION PROCESS
Cold Heading
A processing method that utilizes specialized equipment and molds to induce plastic deformation of raw materials under normal temperature conditions, thereby forming spherical blanks.
Polishing
After cold heading, the ball blanks, under the rotational action of the fixed plate and the rotating plate, have their annular bands, poles, and part of the stock removed by grinding, thereby initially shaping the steel ball blanks into a spherical form.
Heat Treatment
After polishing, the semi-finished steel balls undergo advanced quenching and tempering processes to achieve the required metallographic structure, hardness, and optimal mechanical properties.
Hard Grinding
The surface quality and shape of the steel balls are further improved through grinding by the fixed iron plate and rotating grinding wheel plate under a certain pressure.
Preliminary Grinding
On the ball lapping machine, through the mechanical action of abrasives and lapping plates, the steel balls undergo rolling lapping in the grooves. A small amount of stock is removed by lapping, enabling the steel balls to reach the precision and surface quality specified in the process.
Precision Grinding
On the precision lapping machine, steel balls are processed between two grooved cast iron plates. Using nanotechnology-based micro-powder as the abrasive, and under the combined action of the working pressure of the precision lapping machine and the mechanical rotation of the rotating disc, the steel balls undergo rolling grinding in the grooves of the two plates. A tiny amount of stock is removed through this process, which further improves the surface quality of the steel balls, enhances their spherical accuracy and dimensional precision, thus achieving the processing method for high-precision steel balls.
01 Raw Material
Through comprehensive and multi-dimensional inspections of raw materials, including surface quality, metallographic structure, decarburized layer, chemical composition, and tensile strength, materials that have undergone vacuum deoxidation treatment—with extremely low levels of impurities such as non-metallic inclusions and high cleanliness—are used.
02 Sphere Forming
First, the wire is cut into lengths of a specified size by a cold heading machine. Then, the cut wire blanks are compressed by female and male dies mounted on hemispherical die holders (one on each side), resulting in the formation of spherical parts.
03 Bright Finishing
The forged ball blanks are clamped between two hard cast disks. Pressure is applied to make them rotate, which removes burrs and surface bands. Meanwhile, this process improves the surface roughness of the steel balls and gives them an initial spherical shape.
04 Heat Treatment
The steel balls undergo carburization in a heat treatment furnace, followed by quenching and tempering. This process endows the balls with a carburized layer of a specified depth, as well as desired hardness, toughness, and crushing load.
05 Hard Grinding
Grinding is performed under a certain pressure using a fixed iron plate and a rotating grinding wheel plate, which further improves the surface quality and shape of the steel balls.
06 Intensification
It is a processing method that uses an intensifier to make steel balls collide with each other, causing plastic deformation on the surface of the steel balls for strengthening—thereby increasing the surface compressive stress and surface hardness of the steel balls.
07 Preliminary Grinding
Two cast iron initial grinding disks are used, and abrasive is added. Through a specified pressure and mechanical movement, the surface quality meeting the process-specified precision is achieved.
08 Eddy Current Testing
The AVKIO flaw detector uses eddy current testing to sort out steel balls with various defects, including surface defects (such as flat heads, burrs, indentation damage, rolling damage, cracks, and burn marks), subsurface cracks, and internal material defects.
09 Precision Grinding
Similar to the initial grinding process, two cast iron precision grinding plates are used, and abrasive is added. Under the action of a specified pressure and mechanical movement, the excess material (stock) is removed, further improving the precision and surface quality of the steel balls.
10 Ultrasonic Machine
The spiral cleaning machine is used to improve the cleaning quality while minimizing damage to the surface of the steel balls. Additionally, the cleaning fluid needs to be continuously circulated and filtered to ensure the cleanliness of the steel balls.
11 optoelectronics
Through the optical automatic visual inspection machine, the surface quality of steel balls is assessed to remove products with material defects and processing defects.
12 final inspection
For each batch of steel balls, final inspection is carried out in accordance with process requirements, including roundness, hardness, metallography, stress, and other indicators.
13 anti-rust packaging
Rust-proof oil is used for spray rust prevention, and the packaging is completed in accordance with the customer's packaging requirements.
QUALITY INSPECTION INSTRUMENT
PRODUCTION PLANT
