Forged Steel Ball Engineered for SAG Mills

It is a forged steel ball specifically engineered for use in SAG mills.The grinding media balls can be delivered in diameters ranging from 100 mm to 165 mm (4” to 6.5”).

Diameters and Roundness:

Diameter (mm)	30	40	50	60	70	80	90	100	110	120	125	150
Diameter roundness(mm)	±2				+3, -2			+4, -3				+5, -4
Roundness(%)	≤2				≤3			≤4				≤5

Technical Parameter

Material	Breakage rate	Hardness(HRC)	Impact value(J/cm²）	Drop times(times)	Micro structure
45#	<1%	≥45	≥12	≥8000	M+C
60Mn	<1%	≥55	≥12	≥12000	M+C
65Mn	<1%	≥58	≥12	≥12000	M+C
70Mn	<1%	≥60	≥12	≥12000	M+C
40Cr	<1%	≥55	≥12	≥12000	M+C
70Cr2	<1%	≥58	≥12	≥12000	M+C
B-2	<1%	≥58	≥12	≥15000	M+C
B-3	<1%	≥60	≥12	≥15000	M+C

Chemical composition

Material	C（%）	Si（%）	Mn（%）	Cr（%）	Cu（%）	Mo（%）	P（%）	S（%）	Ni(%)
45#	0.42-0.50	0.17-0.37	0.5-0.80	0-0.25	0-0.25	0-0.30	0-0.035	0-0.035	0-0.30
60Mn	0.57-0.65	0.17-0.37	0.70-1.0	0-0.25	0-0.25	0-0.30	0-0.035	0-0.035	0-0.30
65Mn	0.62-0.70	0.17-0.37	0.90-1.0	0-0.25	0-0.25	0-0.30	0-0.035	0-0.035	0-0.30
70Mn	0.67-0.75	0.17-0.37	0.90-1.20	0-0.25	0-0.25	0-0.30	0-0.035	0-0.035	0-0.30
40Cr	0.37-0.45	0.17-0.37	0.50-0.8	0.80-1.1	0-0.25	0-0.30	0-0.035	0-0.035	0-0.30
70Cr2	0.65-0.75	0.20-0.30	0.75-0.90	0.55-0.70	0-0.25	0-0.30	0-0.030	0-0.030	0-0.30
B-2	0.70-0.80	0.17-0.37	0.70-0.80	0.50-0.60	0-0.25	0-0.30	0-0.035	0-0.035	0-0.30
B-3	0.58-0.66	1.2-1.6	0.65-0.80	0.70-0.90	0-0.25	0-0.30	0-0.035	0-0.035	0-0.30

Advantages of Forged Steel Balls for SAG Mills

Our factory is a leading Chinese manufacturer of forged steel balls, specializing in the R&D and production of grinding media. Its forged steel balls enjoy a strong reputation in domestic and international markets, particularly in industries such as mining, cement, and power generation.

1. Advanced Forging Technology and Processes

– Fully Automated Production Lines: 

The factory has fully automated forging lines combined with modern heat treatment technologies (e.g., continuous quenching and tempering processes), ensuring uniform and dense internal grain structures in the steel balls. This achieves an optimal balance between hardness and toughness. 

– Proprietary Technologies: 

Our factory holds multiple forging process patents (e.g., its “Energy-Saving Hot-Rolled Steel Ball Production Line”), improving energy efficiency while enhancing product consistency. 

2. High-Quality Material Selection

– High-Purity Alloy Steel: 

Premium high-carbon steels (e.g., 60Mn, 65Mn) and alloy steels (e.g., B2, B3) are used, with precise chemical composition control to ensure high wear resistance and impact toughness. 

– Rare Earth Element Modification: 

Some products incorporate rare earth elements to refine grain structures and increase surface hardness (up to HRC 60-65), extending service life. 

3. Rigorous Quality Control Systems 

– End-to-End Testing: 

Strict inspection protocols are applied from raw material intake to final product delivery, including spectral analysis, hardness testing (Rockwell scale), impact testing, and metallographic analysis. This eliminates defects like internal cracks or porosity. 

– International Certifications: 

The company holds ISO 9001 (Quality Management System) and ISO 14001 (Environmental Management System) certifications. Its products comply with global standards (e.g., ASTM, DIN) and are exported to over 50 countries. 

4. Significant Economic Benefits

– Low Wear Rates: 

Our forged steel balls exhibit 30%-50% lower wear rates compared to standard cast balls in both wet and dry grinding conditions, reducing downtime for replacements. 

– Optimized Cost per Ton of Ore: 

Although individual balls have a higher upfront cost, their extended lifespan and lower wear translate to significant savings in total ore processing costs (client-reported savings exceed 20% in some mining operations). 

5. Customization and Product Diversity 

– Wide Size Range: 

Offers steel balls with diameters ranging from 20mm to 150mm, catering to various ball mill specifications (e.g., large semi-autogenous grinding mills). 

– Scenario-Specific Adaptations: 

Adjusts heat treatment processes based on client requirements (e.g., ore hardness, mill rotation speed) to deliver tailored products with enhanced hardness or toughness. 

6. Environmental Sustainability

– Energy-Efficient Production: 

Utilizes waste heat recovery technologies to reduce energy consumption during forging, aligning with green manufacturing practices. 

– Circular Economy: 

Worn steel balls are 100% recyclable, minimizing resource waste and supporting sustainable mining practices. 

7. Market Competitiveness and Client Recognition

– Global Presence: 

Exports to mining hubs such as South America, Africa, and Australia, with long-term partnerships with global mining giants. 

– Industry Reputation: 

Praised by clients as “one of the most cost-effective grinding media suppliers” for outstanding performance in projects like Chilean copper mines and Australian iron ore operations. 

Unique Advantages Over Competitors

– Technical Barriers: 

Fully automated production lines and patented processes ensure consistent quality at scale, which smaller competitors struggle to replicate. 

– Cost Efficiency: 

Economies of scale in procurement and production management enable competitive pricing. 

– After-Sales Support: 

– Provides value-added services like technical consulting and wear analysis to optimize clients’ grinding efficiency. 

– Advanced forging technology guarantees superior performance; 

– Strict quality control and customization capabilities meet diverse client needs; 

– Cost efficiency and global reach secure market leadership. 

For mining and industrial users prioritizing long-term efficiency, our forged steel balls offer an optimal balance of durability, economy, and reliability. For detailed data (e.g., wear rate test reports or case studies), direct consultation with their technical team is recommended.