Grinding Roller
Mill grinding rollers supplied to the Chinese electric power industry
What This Casting Does And Why It Matters
With the new foundry running we became a manufacturing base for the Chinese electric power industry, supplying wear parts including grinding rollers and liners. Grinding rollers are large, heavy, high-wear castings where metallurgy and heat treatment decide the service life, and where a 10-tonne pouring capacity and a 2,000 m³ quench pool are the reason the work is possible at all.
Technical Features
- High chromium white cast iron Cr15, Cr25, Cr30 and alloy steel options
- Bottom-poured from 5 t intermediate frequency furnaces
- Trolley heat treatment furnaces up to 3 m × 3.5 m × 2 m
- Chemical analysis on every heat with samples retained three years
- Non-destructive testing available on request
What You Get That You Would Not Get Elsewhere
Already supplying grinding rollers to the Chinese electric power industry
Single castings up to 10 tonnes poured from bottom-pouring ladles
2,000 m³ quench pool with underwater circulating and stirring
Machined in-house on vertical lathes up to Ø3.4 m
The Failures This Part Is Cast To Prevent
- Large wear castings that few foundries can pour and heat treat
- Grinding rollers wearing unevenly and unbalancing the mill
- No metallurgical documentation supplied with a critical part
- Long lead times on components that determine mill availability
Who It Is For
- Coal-fired power generation operators
- Cement and mineral grinding plants
- Mill rebuild contractors
- Equipment builders sourcing large wear castings
Application Scenarios
- Coal mill grinding element replacement
- Mineral grinding circuits
- Mill overhauls
- Critical spares holding for power plants
Technical Data For Grinding Roller
Every figure here comes from our published foundry capability. Where a value depends on your machine it is confirmed at quotation rather than guessed.
| Specification | Detail |
|---|---|
| Part type | Grinding roller, mill roller |
| Industry supplied | Chinese electric power industry |
| Material options | High chromium white cast iron Cr15, Cr25, Cr30, alloy steels |
| Max single casting weight | 10 t |
| Max machining diameter | Ø3.4 m |
| Melting | 5 t intermediate frequency furnace × 2 |
| Heat treatment | Trolley furnace up to 3 m × 3.5 m × 2 m, 2,000 m³ quench pool |
| Inspection | Spectrometer, hardness, microstructure, dye penetrant, dimensional |
| Packing | Steel pallet |
How This Casting Is Made
Pattern Making
Once drawings are confirmed, pattern making starts immediately in our own pattern shop. Thousands of finished patterns are already on the shelf, so repeat parts skip this step entirely.
Sandbox Making
Casting Process Simulation System (CPSS) is run before the moulds are made. The cavity is kept as solid and as clean as possible so that inclusions have nowhere to start.
Melting And Pouring
Charge materials are bought to a high standard and temperature is controlled through the whole pour to achieve a fine grain structure. Samples are taken to verify the analysis and adjusted if needed, then kept for at least three years for traceability.
Sandbox Opening
Also called casting cleaning. After initial cooling the box is opened, risers and runners are removed and the casting is cleaned. Cooling time is set by casting size, not by the clock.
Heat Treatment
Heating temperature is strictly controlled and castings are spaced in the furnace so they heat uniformly and meet the water fully. Quenching begins within 30 seconds of withdrawal from the oven.
Machining
After rectifying and polishing, castings are machined strictly to drawing for correct fitment. QC then carries out dimensional inspection and issues the dimensional inspection report.
Inspection
Our own physical and chemical laboratory covers spectrometry, hardness, microstructure, dye penetrant and dimensional inspection on site rather than at a third party.
Packing And Delivery
Finished parts are packed on steel pallets for forklift handling, to international standards for road, rail, sea and air transport.
Inspection Supplied With This Part
Chemical analysis and a dimensional inspection report are standard on every order. The remaining procedures are carried out in our own physical and chemical laboratory when specified at order stage.
| Procedure | When |
|---|---|
| Chemical Analysis | standard on every heat |
| Dimensional Inspection Report | standard on every order |
| Hardness Testing | if specified |
| Tensile Testing | if specified |
| Microstructure Analysis | if specified |
| Magnetic Particle Testing | if specified |
| Dye Penetrant Testing | if specified |
| Ultrasonic Testing | if specified |
Laboratory Equipment
- German-made OBLF direct-reading spectrometer
- Hardness testing equipment
- Metallurgical microscope
- Dye penetrant inspection equipment
- Dimensional inspection equipment
How This Part Compares With The Alternatives
| Compared With | What Changes |
|---|---|
| A smaller foundry | Ten-tonne pouring capacity, trolley heat treatment furnaces and a 2,000 m³ quench pool are what make a roller of this size possible. |
| Weld rebuilding a worn roller | Overlay leaves an uneven surface and a heat affected zone. A new casting has documented chemistry through its section. |
| Buying without inspection records | Chemical analysis is standard on every heat here and samples are retained for three years. |
If Your Part Is Not Standard
With our own pattern shop, a 3D scanner and Casting Process Simulation System, we work from your drawing, your worn sample, or a scan taken on your site. Material grade, profile and machining are all specified against your machine rather than against a catalogue.
- Reverse engineering from a worn part, with no drawing required
- On-site 3D scanning where the component cannot be removed
- Material grade selected against your feed rather than a default
- Pattern retained afterwards, so repeat orders skip pattern making
Fitting And Getting The Life Out Of It
- Supply the mill type, roller drawing and material specification with the enquiry
- Specify any non-destructive testing required at order stage
- Replace grinding elements as a set to keep the mill balanced
- Retain the inspection report against the next order
Grinding Roller At The Foundry
Parts Usually Ordered Alongside This One
Mill Liner
Mill liners in manganese and high chromium for grinding circuits
View Part →
Reverse Engineered Wear Castings
From a worn part with no drawing to a repeatable casting
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Smooth Surface Roller Shell
Smooth-faced shells for controlled reduction, cast by an OEM roller supplier
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Bowl Liner And Concave
The fixed half of the cone crushing chamber, cast in seven manganese grades
View Part →Guides That Cover This Part
Heat Treatment Of Crusher Wear Castings And Why 30 Seconds Matters
Solution treatment and quenching decide whether a manganese casting is tough or brittle. The controls that make the difference are simple and unforgiving.
Read Guide →
What Casting Process Simulation Changes Before The Mould Is Made
CPSS runs before sand is packed. It is the cheapest opportunity to find a shrinkage cavity — on screen rather than in a finished casting.
Read Guide →Grinding Roller Questions
Do you already supply the power industry?
Yes. With our new foundry running we became a manufacturing base for the Chinese electric power industry, supplying wear parts such as grinding rollers and liners.
How large a roller can you cast?
Single castings up to 10 tonnes, machined up to Ø3.4 m.
What heat treatment capacity do you have?
Trolley furnaces up to 3 m × 3.5 m × 2 m and a 2,000 m³ quench pool with underwater circulating and stirring.
What documentation is supplied?
Chemical analysis and a dimensional inspection report as standard, with hardness, microstructure and NDT if specified.
Get A Price For Grinding Roller
Send the machine model, the part number if you have one, and the quantity. If you have neither, a photograph with the main dimensions is enough to start.