This work presents a scheme for the manufacture of spherical grinding bodies used in grinding and crushing machinery as a grinding medium from abrasion-resistant cast iron CHKH16 (according to GOST 7769-82) free of shrinkage defects produced by casting into single sand molds with a vertical joint and by usingcoolers. The grinding efficiency in terms of material destruction and energy consumption has been studied according to a wide range of operating parameters and new scheme for calculating the sprue and supply system has been developed by the authors of the article. Its functionality has been substantiated, particularly the use of a central riser acting as a head and the use of coolers. The conducted numerical simulation has shown the dependence of a solid phase formation over time, which characterizes the direction of the system crystallization and determines the locations of the shrinkage defects concentration. The manufacture of the grinding body with a 100 mm diameter using the considered technology is presented in this paper.
The paper presents the initial results of investigation concerning the abrasion resistance of cast iron with nodular, vermicular, or flake graphite. The nodular and vermicular cast iron specimens were cut out of test coupons of the IIb type with the wall thickness equal to 25 mm, while the specimens made of grey cast iron containing flake graphite were cut out either of special casts with 20 mm thick walls or of the original brake disk. The abrasion tests were carried out by means of the T-01M tribological unit working in the pin-on-disk configuration. The counterface specimens (i.e. the disks) were made of the JT6500 brand name friction material. Each specimen was abraded over a distance of 4000 m. The mass losses, both of the specimens and of the counterface disks, were determined by weighting. It was found that the least wear among the examined materials was exhibited by the nodular cast iron. In turn, the smallest abrasion resistance was found in vermicular cast iron and in cast iron containing flake graphite coming from the brake disk. However, while the three types of specimens (those taken from the nodular cast iron and from grey cast iron coming either from the special casts or from the brake disk) have almost purely pearlitic matrix (P95/Fe05), the vermicular cast iron matrix was composed of pearlite and ferrite occurring in the amounts of about 50% each (P50/Fe50). Additionally, it was found that the highest temperature at the cast iron/counterface disk contact point was reached during the tests held for the nodular cast iron, while the lowest one occurred for the case of specially cast grey iron.