Heavy-Duty Precision Engineering for Grinding Systems
In mineral processing, cement manufacturing, and power generation, ball mills operate under intense, constant kinetic stress. Structural integrity cannot be compromised.
Openex specializes in the turnkey fabrication and large-scale machining of massive segmented ball mill components. We frequently fabricate heavy-wall cylinders, feed/discharge end assemblies, bolted ring joints, and trunnion bearing housings capable of withstanding extreme vibration, load impacts, and daily rotational wear. Backed by an Innse-Berardi floor borer and a massive 22-meter vertical turning lathe, we produce shells up to 15 meters in diameter and weighing over 90 tons.
Technical Manufacturing Tolerances
Matching immense size with micron-level tolerances is an extreme engineering challenge. Openex holds extremely strict precision standards, continuously verified using on-machine measurements and heavy-capacity CMM equipment.
| Parameter | Openex Machining Capability |
|---|---|
| Max Component Diameter | 15,000 mm (15 Meters) |
| Flange Welding Thickness | Up to 190 mm joints |
| Flange Face Verticality | ≤ 0.05 mm |
| Shell Runout Tolerance | ≤ 0.05 mm |
| Bolt Hole Positional Accuracy | Controlled within 0.05 mm across the entire face |
| Machined Surface Roughness | ≤ 3.2 µm |
Our 6-Stage Manufacturing Flow
Structural steel plates (Q235B, Alloy Steels) are precisely cut and prepped with edge bevels, followed by heavy rolling to form the 83mm thick massive shell curvature.
Segmented shell bodies, structural rings, and bolting flanges undergo continuous heavy welding that is meticulously controlled per AWS and ISO 3834 codes.
Crucial for minimizing structural warp and maximizing life span, components are placed inside massive furnaces for deep Post-Weld Heat Treatment (PWHT).
Machining operations utilizing floor boring centers maintain concentricity via carefully managed thermal-stable feeds and speeds. Multi-axis heads process precision, closely-spaced bolt hole radial arrays perfectly.
100% of weld joints receive Ultrasonic Testing. Final structural analysis happens under CMM verifications and laser trackers across the shop floor.
Weight & Heat Management Challenge
Handling partially finished structures exceeding 90 tons creates immense physical risk and risks heat distortion from ambient gravity-stress while machining. We employ specifically manufactured heavy fixtures, rotation rigs, and rigid support jacks that completely offset dead-load deflection while milling.