ball manufacturing and properties

8/10/2019 BALL MANUFACTURING AND PROPERTIES

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DSP-BALLS: PRODUCTION LINES OF PRECISION BALLS

Production lines for Precision Balls are stream-lined with optimum combinations of various processes. The processgiven below illustrate how the high Quality of High Carbon High Chrome Steel balls are achieved

Raw Material

Also known as, Bearing Steel Balls, they are the most critical and specialized element of bearing. They are produced using extremelysophisticated and specialized machines.

Starting from the rigorous testing of the wire for all necessary parameters, balls are produced in specially designed machines calledHeadder, Flasher, Grinder and Lapper. Heat treatment is one of the most critical operations which gives required strength &hardness. It makes the balls tough and wear resistant. Apart from intermediate vigil at all operations, for all quality parameters,finished products are also tested with extremely sophisticated equipments to ensure right quality of DSP Balls.

TENSILE STRENGTH 228 kgf/mm2

MODULUS OF ELASTICITY 20750 kgf/mm2

SPECIFIC WEIGHT 7.83 kgf/cm3

HARDNESSBETWEEN 58-65 HRC

( measured on parrel flats)

COMPONENT C Si Mn Cr P & S

CONTENT (%) .98-.1% 0.15-0.30 0.15-0.45 1.3 -1.6 0.025 MAX


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Is thoroughly inspected for Physical & Chemicals properties.

Heading

Wire coils are cold forged into spherical blanks, for compact structure, in semi-automatic machines known as singlestroke Headers.

Flashing / Filing

Die-marks on poles and equator of headed blanks are then removed by grinding them between hardened plates ofspecial composition, known as Flashing / Filing.

Heat Treatment

Balls are heated in controlled environment to critical temperatures & quenched to attain due hardness. Balls arethen tempered to close limits.

Grinding

Balls are ground to close tolerances in special machines with different grades of abrasives for final lappingprocesses.

Lapping

Balls are lapped for final parameters of size, sphericity , lot variation and to surface quality in a series of speciallydesigned machines known as Lappers.

Cleaning

Balls are then prepared for macro inspection by thorough cleaning in a especially designed cleaning machine.

Macro Inspection

Whole production of DSP-BALLS goes through 100 % inspection by well trained inspectors, under suitablemagnification and light, for all surface defects.

Super finishing

Balls passed through macro inspection goes under super finishing and all Specified parameters are maintained inrequired tolerances as per grade to be prepared.

Guarantee Test

During production balls are inspected at every stage for fixed stage specifications, and the material is unloadedfrom the machines only on qualifying limits. Finally, during super finishing, parameters of geometry, lot variation andsurface roughness etc. are re-ensured and detailed inspection report is prepared and supplied to the customer ondemand.

Packing

Rust Prevention Oil is applied on the balls . They are then double packed in polythene bags, before being packed inCardboard boxes and wooden cases. Labels carrying details of sizes, quality are properly pasted.

Cargo to Export

Balls so packed are ready for Export to customers.


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Also known as, Carbon Balls, they are mostly in place of Bearing Steel Balls where expected wear and tear is less. They areproduced using extremely sophisticated and specialized machines.


TENSILE STRENGTH 228 kgf/mm2

MODULUS OF ELASTICITY 20750 kgf/mm2

SPECIFIC WEIGHT 7.83 kgf/cm3

HARDNESSBETWEEN 58-65 HRC

( measured on parrel flats)

COMPONENT C Si Mn P S

CONTENT (%) 0.11-0.20 0.15-0.35 0.5 MAX 0.025 MAX 0.025 MAX


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Production lines for Precision Balls are stream-lined with optimum combinations of various processes. The processgiven below illustrate how the high Quality of High Chrome Steel balls are achieved

Raw Material


Heading


Flashing / Filing

Die-marks on poles and equator of headed blanks are then removed by grinding them between hardened platesof special composition, known as Flashing / Filing.

Heat Treatment

Balls are heated in controlled environment to critical temperatures & quenched to attain due hardness. Balls arethen tempered to close limits.

Grinding

Balls are ground to close tolerances in special machines with different grades of abrasives for final lappingprocesses.

Lapping


Cleaning


Macro Inspection


Super finishing

Balls passed through macro inspection goes under super finishing and all Specified parameters are maintained inrequired tolerances as per grade to be prepared .

Guarantee Test


Packing

Rust Prevention Oil is applied on the balls . They are then double packed in polythene bags, before being packed inCardboard boxes and wooden cases. Labels carrying details of sizes, quality are properly pasted..


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Cargo to Export


DIFFERENT GRADES FOR STAINLESS STEEL BALLS

SPECIFICATIONS EQUIVALENTS HARDNESS AVAILABLEGRADES

PROPERTIES

AISI 420 C W.1. 4034 AFN. Z 40 C 13B.S. 420 S 45 DIN X 40

Cr 13

35 HRC 10 & Above 420 C balls offer good hardness & surface finish. Theyare generally used for all applications requiring corrosion

resistance to water. Steam water, air, gasoline. Notrecommended for applications requiring resistance to

most chemical solutions.

AISI 440 C W. 1.4125 AFN. Z 100 CD17 DI.X 105 Cr. M0 17

58 To 65 HRC 10 & Above 440 C balls afford the advantage of maximum hardnesscombined with corrosionresistance properties. The

hardness together with accuracy and fine surface finish,makes them especially used for both bearing & valve

application & other severe applications.

AISI 302 W. 1.4319 AFN Z 10 CN1809 B.S. 302 S25 DIN X

12 Cr Ni 18 .8

25-39 HRC OR140-160 HB

48 & Above Austenistic unhardened stainless steel balls withexcellent toughness and resistance to corrosion by suchagents as oxidizing solutions, most organic chemicals,

food stuffs and sterilizing solutions. They have non-magnetic properties.

AISI 304 W 1.4301 AFN. Z 6 CN18.09 B.S. 304 S 15 DIN

X Cr Ni 189

25-39HRC OR 140-

160 HB

48 & Above As above but with Lower carbon content.

Balls are made from many different varities of Stainless Steel. They are used for application where prevention of rust is desireable.They are also use for areas where non-magnatic properties are called for. They are produced using extremely sophisticated andspecialized machines.



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AISI 316 W. 1.440 AFN Z 6 CN D1711 B.S. 316 S 16 DIN X

Cr Ni Mo 1810

25-39HRC OR 140-

160 HB

24 & Above Austenitic unhardened stainless steel balls as above buwith increased nickel and addition of molybdenum. This

is giving much better corrosion resistance to strongacids (sulfuric, phosphoric & acetic). Can be used to

elevated temperatures.

AISI 316-L W. 1.4404 AFN Z 2 CN

1712 B.S. 316 S12

25-39

HRC OR 140-160 HB

48 & Above As above but with lower carbon content and increased

nickel.

DIFFERENT GRADES FOR STAINLESS STEEL BALLS

SPECIFICATIONS EQUIVALENTS COMPOSITION %

C Si Mn P S Cr Mo Ni

AISI 420 C W.1. 4034 AFN. Z 40 C 13 B.S.420 S 45 DIN X 40 Cr 13

0.40To

0.50

1.00max

1.00max

.045max

.030max

12.0 To14.0

- -

AISI 440 C W. 1.4125 AFN. Z 100 CD 17DI.X 105 Cr. M0 17

0.95To

1.20

1.00max

1.00max

0.045max

0.03max

16.0 To18.0

0.4 To0.8

-

AISI 302 W. 1.4319 AFN Z 10 CN 1809B.S. 302 S25 DIN X 12 Cr Ni 18

.8

0.12max

0.2 To1.00

0.5 To2.0

0.045max

0.03max

17.0 To19.0

8.0 To11.0

-

AISI 304 W 1.4301 AFN. Z 6 CN 18.09B.S. 304 S 15 DIN X Cr Ni 189

0.07max

1.00max

2.0max

.045max

0.03max

17.0To 20.0

-8.50 To

10.5

AISI 316 W. 1.440 AFN Z 6 CN D 1711B.S. 316 S 16 DIN X Cr Ni Mo

1810

0.07max

1.00max

2.00max

0.045max

0.03max

16.5 To18.5

2.00 To2.5

10.5 To13.5

AISI 316-L W. 1.4404 AFN Z 2 CN 1712 B.S.316 S12

0.03max

0.20 To1.00

0.50To

2.00

045max

0.03max

16.5 To18.5

2.25To14.0

10.0 To14.0



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Production lines for Precision Balls are stream-lined with optimum combinations of various processes. The processgiven below illustrate how the high Quality of Stainless Steel balls are achieved

Raw Material

Is thoroughly inspected for Physical & Chemicals properties .

Heading


Flashing / Filing


Lapping


Cleaning


Macro Inspection


Super finishing


Guarantee Test


Packing

They are then double packed in polythene bags, before being packed in Cardboard boxes and wooden cases.Labels carrying details of sizes, quality are properly pasted..

Cargo to Export



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Copper balls.

These Balls are mostly used for non-bearing applications. Their properties of ductility, good corrosion resistance in moisture andelectricity conductivity find them allied applications in machines and components

Starting from the rigorous testing of the wire for all necessary parameters, balls are produced in specially designed machines calledHeadder, Flasher and Lapper. Apart from intermediate vigil at all operations, for all quality parameters, finished products are alsotested with extremely sophisticated equipments to ensure right quality of DSP Balls.

TYPEJIS

FEATURE HARDNESSHB

TENSILESTRENGTH

kg/mm2

SPECIFICWEIGHT(gf/cm3)

C2700 Good corro. resistance in ambient air and seawater, unstable in acid and alkalis

75 45 8.53

C3604Good corro. resistance in ambient air and sea

water, unstable in acid and alkalis75 45 8.53

TYPE CHEMICAL COMPOSITION

JIS Name Cu Zn

C2700 Brass


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These Balls are mostly used for non-bearing applications. Their properties of electricity and heat conductivity and good corrosionresistance in moisture find them allied applications in machines and components. Balls are also produce from various alloys copperas well.

Starting from the rigorous testing of the wire for all necessary parameters, balls are produced in specially designed machines calledHeadder, Flasher and Lapper. Apart from intermediate vigil at all operations, for all quality parameters, finished products are alsotested with extremely sophisticated equipments to ensure right quality of DSP Balls.

TYPEJIS

FEATURE HARDNESSHB

TENSILESTRENGTH

kg/mm2

SPECIFICWEIGHT(gf/cm

3)

C1100 Extreme softness and very high conductivity. 55 35 8.86

Has great creep resistance in a hardenedcondition. It is corrosion resistant and has arelatively high electrical conductivity. Isessentially non-magnetic and has extremelygood fatigue strength.

TYPE CHEMICAL COMPOSITION (%)

JIS NAME Cu Zn Sn

C1100 Copper 99.9

BC2 Bronze 88.0 4.0 8.0


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Production lines for Precision Balls are stream-lined with optimum combinations of various processes. The processgiven below illustrate how the high Quality of Copper balls are achieved

Raw Material


Heading


Flashing / Filing


Lapping


Cleaning


Macro Inspection


Super finishing


Guarantee Test


Packing

They are then double packed in polythene bags, before being packed in Cardboard boxes and wooden cases.

Labels carrying details of sizes, quality are properly pasted..

Cargo to Export



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