LITERATURE REVIEW

2.1 Introduction
Ball milling is the dominant process of shear forces in which particle size continues to
decrease due to impact and shift mainly consists of metal balls that act as a grinding medium
and rotating shell to create centrifugal force. In this process, collisions between graphite and
small metal balls in the container will produce a local high pressure either shear or
compression force. As a result, all the impact of the metal balls received by graphite makes
its grinds into a fine powder. Usually, ceramic, flint pebbles, and stainless steel are used.

Ball milling is a process that can create a variety of functional materials by mechanochemical
synthesis. Mechanochemical synthesis is a technique that interplay between mechanical and
chemical energies at the molecular scale.

Figure 1: ball milling process

Figure 1 shows the process of ball milling inside a hidden container. The
rotating of the grinding bowl makes the graphite continuously strike with grinding media to
create centrifugal force. Unfortunately, the continuous excessive compression force may
damage certain graphite such as crystalline that needs to slow down the process by
controlling the milling parameters. For example, milling duration, milling revolution per
minute (rpm), initial graphite weight, and ball diameter. By emphasizing these things, high-
quality graphene can be achieved.
2.2 Comparison between old ball milling and new ball milling

Ball mill machines are widely used in industries, such as cement, silicate products,
refractories, fertilizers, ferrous and non-ferrous metal mineral processing, and glass-ceramics.
This ball-milling is mainly used to grind big particles of graphite into fine particles

The ball mill is a horizontal rotating device transmitted by external gear. The
materials are uniformly delivered to the grinding chamber via the quill shaft. In the chamber,
there are stepped lining boards and corrugated liner boards, as well as various steel ball
specifications. The steel balls are raised to a given height by the centrifugal force created by
the barrel movement, which impacts and grinds the materials.

The ball milling underwent an evolution through the years eithers in diameter of steel
ball, milling duration or initial graphite weight. High-energy ball milling is considered as new
version ball milling. High-energy ball milling is a mechanical deformation method used to
produce nanocrystalline metals or alloys in powder form.

No BALL MILL HIGH-ENERGY BALL MILL

1 Ball mill is used to grind the pieces of High energy ball mill is used to grind
raw material into powder-like structures. nanocrystalline materials
2 The particles can be ground to 5 nm. The particles can be ground from 4 to
26 nm.
3 Used a lot of power motor Used less of power motor
4 The cost of production is height The cost of production is low
5 The ratio of balls to material is 4:10 The ratio of balls to material is 10:2
6 Consume a lot of time to grind the Consume a short of time to grind the
materials materials.
7 Work for big particles of materials Only works for small particles of
materials.

2.3 Components of ball milling

 Figure 2: ball milling

1. Three-phase motor: to drive the ball mill

2. Gearbox: used to reduce the speed of the motor driving the ball mill
3. Ring gear: this component is connected on the drum’s outer diameter
4. Drum: this component is the cylindrical casing of the ball mill. The inside of the
drum is lined with manganese steel alloy plates that are used for protection for the
steel shell from abrasion, instead of manganese steel, rubber also can be used as a
protection or known as armor. Rubber usually used in ball mills in the ore mining,
processing industry which are the second and third stages of grinding, construction
industry which is the production of concrete and brick and cement and ceramic
industries. As for the steel, this material used in the mining industry which is the
initial stage of grinding, energy-generating plants (TPP) and the cement industry.
5. Bearing: Used to smoothen the ball mill drum’s rotation by reducing friction. Anti-
friction cylindrical roller bearings are used in smaller ball mills. Trunnion bearings
are used in larger ball mills.
6. Discharge: the discharge is where the mill’s decreased feed exits
7. Inlet: the inlet is used to feed crushed ore to the ball mill. The feed to the mill is kept
consistent with the use of a scoop.
8. Motor: The drum is rotated by a motor. Instead of a ring gear, the motor drive train
leads to a gearbox. To adjust the rpm of the ball mill, the motor is frequently equipped
with a variable speed drive (VSD)
2.4 Ball milling gears

For ball mill drives, there are two general gearing classifications. The spur gear and the
helical gear are the two types of gear. Helical gearing can be single-helical or double-helical
(Herringbone) in design.

i. Spur gears
Spur gears are commonly offered on the lower diameter mills employing V-belt
drives or reducer drives. Spur gears and pinions are made with full depth involute
tooth type thereby insuring optimal tooth strength and extended wearing life. The
primary gear is made split and reversible and made of an unique Meehanite metal
casting. All spur gears and pinions are meticulously machined, and the teeth are
precisely cut to provide the optimum tooth shape and spacing, hence maximizing the
greatest possible tooth strength and wear rating.

Figure 3: spur gears

ii. Helical gears
Helical gears are employed for bigger diameter mills that will be directly coupled to a
low-speed motor. There are two main reasons to use helical gearing on this drive
arrangement. First, it is to allow for larger gear ratios than can be done with spur
gears. As a result, a higher-speed, and less-cost motor may be used. Second, there are
no intermediary transmission element such as a V-belt drive, so overlapping tooth
movement became more smooth. The full depth tooth shape is used to cut all helical
gears and pinions. The pinion, which is normally attached to the pinion shaft is made
from an alloy steel forging that has been heat-treated before the teeth are cut. The
primary gear is split and reversible and created from an unique gear steel casting. All
ball mill gears are developed with a strong technical concept while making it into
 long-term economics. In order to allow for future changes in power or capacity needs,
very high ratios or a pinion with a small number of teeth, are usually avoided. Hence,
the primary gear and pinion do no need to be replaced completely. In conclusion, all
gears and pinion are a medium to withstand the dynamic overloads experienced in this
service and to work well.

Figure 4: Helical gears

2.5 Milling medium- balls

i. Balls are typically made of manganese alloy steel. The types of material used depends
on the substance that the mill will grind. Other materials available are chrome steel
alloy, stainless steel, and rubber.
ii. The diameter of the balls is determined by the size of the drum, common ball
diameters range from two to four inches. High density and larger balls have more
impact energy when they collide, hence producing greater results.
iii. Weight of balls should be more heavy than the material to be grind
iv. Larger balls create smaller grain size

References
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