ia PU SMILD isl INSTRUKTIONER INSTRUCTIONS —_—INSTRUCTIONS ANWEISUNGEN — INSTRUCCIONES —_INSTRUCOES v 2821-05 | 1/23 MANUFACTURE OF CAST LINING PARTS FOR MILLS. Page: 1.__ GENERAL 2 APPROVAL OF SUPPLIER 2 3. TRIAL CASTING 2 4. LINING PARTS OF DUCRODAN, Mat. 361, 362 and 363 3 5. LINING PARTS OF OTHER MATERIALS a MACHINING 8 71. DIMENSIONS, TOLERANCES, MEASUREMENTS 8 8. PACKING INSTRUCTIONS 18 N-PBV 2821-05 ate 1. GENERAL the requirements in this instruction manual must be adhered to strictly, because defective mill’ lining castings may involve high expenses for client, supplier and FLS. 2. APPROVAL OF SUPPLIER To obtain approval as supplier of mill lining castings to FLS, the following conditions must be met: 1. The foundry must be equipped with an electric furnace. - 2. The laboratory must be able to make hardness tests and spectography. 3. FLS (Material Laboratory) must approve samples of similar goods. Samples forwarded for approval must be accompanied by material analyses of the composition, hardness and heat treatment. Production to order must not begin before permission has been given. 3. TRIAL CASTING Trial casting. Before the production of the first series of a casting is started, trial castings must always have been approved by the FLS inspector. 3.1 Certificates. FLS must have certificates forall lining castings, specifying analysis, hardness, heat treatment and information about any other tests, if any.Vv 2821-05 LINING PARTS OF DUCRODAN Ducrodan is cast steel with a high content of chromium. Ducrodan has .a high wear resistance and good impact resistance. 4.1 Analysis of Mat. 361 and 362: C 2.6 - 2.8% si max. 1.0% Mn max. 1.0% Cr 25 - 27% Structure. See Fig. 1. The structure must be hypoeutectic or slightly eutectic (1 or 2). Hypereutectic structure (3) is not acceptable:V 2821-05 -4- Hypoeutectic Eutectic : Hypereutectic 1. 2. 3V 2821-05 aoe 4.2 Ducrodan Mat_361. Mat. 361 has a higher wear resistance, but is less impact resistant than Mat. 362. The structure must be eutectic or slightly hypoeutectic with chromium carbides in the martensitic matrix. The hardness must be HB 550-650. Lining plates having a thickness of less than 50 mm do normally not require heat treatment. If the required minimum hardness is not obtained, however, heat treat as follows: Heat treatment at 1000°c for 4 hours followed by cooling in the air. 4.3 Ducrodan Mat. 362. Mat. 362 has a higher impact résistance, but less wear resistance than Mat. 361. The structure must be eutectic or slightly hhypoeutectic with chromium carbides in a ferritic matrix (Fig. 1 or 2). The hardness must be HB 350 - 450. Heat treatment must be made at 750° Cc for 12 hours follgwed by cooling in a furnace to approx. 300° C and finally air cooling.Vv 2821-05 6 4.4 Special Ducrodan Mat. 363. Mat. 363 has the same wear resistance as Mat. 361, but a better impact resistance. Analysis: c 1.7 = 1.9% Si max. 1.0% Mn 0.8 - 1.2% cr 14 = 16% Mo 0.7 - 0.8% The structure must consist of chromium carbides in a martensitic matrix. The hardness must be HB 500-600. Heat treatment To obtain the properties specified on the Mat. sheet, apply the following heat treatment: 1. Destabilising heating a) Sloy heating from rogm temperature to 800° Cc. Max. 50° C/h. Holding time approx. 3 hours. b) Slow cgoling in furnace to 400° c. Max. 15° C/h. c) Air cooling. 2. Hardening a) Slow heating from 200° ¢ to 970° c. Max. 50° C/h. b) Holding time: 4 hours. c) Air cooling. 3. Double tempering: a) 00° c. Holding time: 4 hours. air cooling. b) 250° c. Holding time: 5 hours. air cooling. NOTE! If hardness HB 500-600 cannot be obtained, increase the temperature for the first tempering.V 2821-05 aye 5. MANUFACTURE OF CAST LINING PARTS OF OTHER MATERIALS. 5.2 Manganese steel. Mat. 330. Analysis of manganese steel for lining parts: © 1.1 - 1.2% si approx. 0.4% Mn 12 ~ 14% PB max. 0.07% Heat,treatment must be slow jheating to 1050°°C. Up to 300°C at 50° c/n. Then cooling inwater bath. - NOTE! When re-using cut-off risers, they imust be melted in an induction furnace so that the hydrogen content in the melt does not become too high. 5.2 Chromium-molybdenum steel Mat. 33d. Directive analysis: c 0.8% CE 2% Mo 0.4% Hardness 350 - 400 BB See also Mat. sheet 33d. To obtain the properties specified on the Mat. sheet, the following heat treatment can be applied: 1. Heat tregtment, 400° c for 3 hours, then 960° C for 4 hours. Cooling in insulated box (24 hours).V 2821-05 2. Heat treatment 850° c for 1 hour. Increase the temperature to 980° c holding time for 30 minutes. The lat- ter operation should preferably be made fast so as not to make the structure coarse grained. 3. Air hardening in calm air. 4. Tempering at approx. 600° c for 30 minutes. 6. MACHINING The suspension sectors for the diaphragms in Mat. 320 must be machined so that the joint face against the mill tube is at right angles to the joint faces for the supporting plates of the diaphragm. DIMENSIONS, TOLERANCES _, MEASUREMENTS 7. Dimensional tolerances. The tolerances for Tength and width dimensions have been determined so that there will be min. distance between the lining plates. This is to prevent pieces of grinding media from getting wedged between the lining plates so that they will become displaced. 12 Tolerances of form and position. Tolerances of form and position have been introduced so as to obtain a mill lining, the dimensions of which are as homogeneous as possible. The tolerances can be adhered to without grinding, ‘through careful work with pattern and casting layout. Fig. 2 shows the symbols that may be used on drawings of the material in connection with tolerance determination in relation to form and position tolerances.2820-05 fig.2 v 2821-05 Properties subject to tolerance Independent elements Lf J Form Straightness Planeness Roundness cylindricity Profile form Surface form Dependent elenents Direction Parallelism S Perpendicularity Angle trueness see Position Position Concentricity and coaxiality O/@}N |F Symmetry Warp Fig. 2V 2821-05 -10- DEFINITION OF TOLERANCE RANGE Ts cd. Tolerance of profile shape. Correct geometrical 1 profile The tolerance range is limited by two covering curves which are tangent to all circles having the diameter "t", the = centres of which are situated on 4 line which has the correct geometrical shape. [A[o,04 In each section parallel to the projection plane, the profile must be situated between two lines which are determined by circles having a diameter of 0.04, the centres of which are situated on a line which has the correct geometrical shape. The correct geometrical shape is determined by means of the framed dimensions (nominal dimensions).V 2821-05 all 7.3.2 Tolerance of parallelism for a surface in relation to @ reference plané. Reference plane The tolerance range is limited by two parallel planes with a mutual distance "t" and parallel to the reference plane. Too) See D The upper surface must be situated between two planes with a mutual distance of 0.01 and parallel to surface D (reference plane).V 2821-05 aig All points on the upper surface must, within a length of 100 and in any position and direction on this surface, be situated between two parallel planes having a mutual distance of 0.01 and parallel to the lower surface (reference plane). $e3.9 Tolerance of position for a point. ball gt ot. ~~ Point subject to tolerance The tolerance range is limited by a spherical surface or a circle having a diameter "t" and its centre in the theo- retically correct position of the point.V 2821-05 “13+ (loos | 709] | The point of intersection must be situated within a circle having a diameter of 0.3 and its centre in the theoretically correct position of the point. Zz Fig. 3a and 3b shows an example of tolerances of form and position, as given on the drawings.V 2821-05V 2821-05 =t6= 14 Gauges. Check all horizontal lining plates Toe with templates and gauges as shown in Figs. 4 and 5. Check Dragpeb lining plates for warpage with template "b", Fig. 5. The parts list refers to the dwg. No. for the relevant gauge. Check other lining plates for warpage with similar templates made of wood or steel plate. Check vertical lining plates by placing them on the floor on which outside dia= meters, inside diameters, bolt circle diameters etc. have been plotted.so-0787 AV 2821-05 ~16- 28 Hardness measurements. Casting samples from new suppliers will be hardness-tested over the entire cross section. Continual hardness tests must be made at random of 10% of the ordered volume. A ball of tungsten carbide must be used for Brinell tests. Steel balls are too soft for Ducrodan testing. 8. PACKING INSTRUCTIONS The goods are forwarded unpacked or in crates. Follow the directions given below: 8.1 Unpacked goods Assemble the lining parts with 930 through- going bolts or retainer irons having an excess length of 80 - 100 mm at either end, intended for strapping. The piece weight must not exceed 1000 kgs. Assemble lining parts as shown with plane surfaces facing each other in pairs. Lining parts of Ducrodan and chromium molybdenum: These parts must not be subjected to bending stresses when tightening up the bolts. this is avoided by using distance pieces. Lining parts with one through-going bolt hole must be assembled with through-going bolt and be secured with two steel straps. See Fig. 6.V 2821-05 -19- 8.3 Lining parts with two through-going bolt holes must be assembled with two through- going bolts. See Fig. 7. 8.4 Lining parts with angle base must be assembled with retainer irons and possibly spacer pipes and similar. See Fig. 8.V 2821-05Vv 2821-05 -21- Fig. 7V. 2821-05 -22- Fig. 8V 2821-05 -23- 8.5 The following lining parts are forwarded in crates made to instruction manual 12951: Packing of goods. Lining parts having a piece weight of less than 16 kgs. For instance Dragpeb lining plates. 8.5.2 Lining plates which are impossible to assemble. For instance lining plates for mill heads. Lining parts of Ducrodan or chromium molybdenum steel which are subjected to bending stresses when they are assembled. For instance corrugated lining with collar. 8.5.4 Lining parts with a high degree of outside machining. For instance | retainer ring segments. =--000---