Computer Simulation of a New Two-Threaded Roll Pass Design for Rolling 100 mm Grinding Balls Made of Alloyed Steels

The production of 100 mm grinding balls using rolls with double-threaded pass design and a discretely variable pitch is characterized by increased roll wear, which leads to characteristic surface defects on the balls. A new roll pass was designed, rolls were made, and pilot 100 mm grinding balls were rolled using new double-threaded rolls. The results of simulating the process of rolling balls and analyzing the stress–strain state of the rolling process are presented. According to the simulation results, the use of the roll pass design with a constant pitch reduces the stress throughout the volume of the deformed metal. The reduced vertical roll angle in the new pass design also reduces the stresses and, as a result, the wear of the rolls.