Heavy Duty Ball Mill End Cover Feed Integral Type Casting Mining Grinding

Integrated Ball Mill Head Casting Custom Cast Steel for Mining

Product Description

Ball mill end‑cover, also known as trunnion head, forms the two end sections of ball mill, AG and SAG grinding equipment. Unlike replaceable head liners which take abrasive wear, this is a permanent main‑structure casting undertaking massive static weight plus recurring cyclic dynamic loads during mill rotation.

It consists of flange disc and hollow trunnion journal. The outer flange bolts firmly to mill shell, and hollow trunnion rests on main bearing assemblies. Feed‑side end‑cover guides incoming ore into grinding chamber, while discharge‑side unit controls material outflow. Stress peaks concentrate on fillet transition zones between thick‑wall trunnion and disc, where hidden casting defects may propagate into fatal fatigue cracks under long‑time cyclic load.

To mitigate such risks, we adopt casting process simulation before steel pouring to optimise gating‑riser layout and minimise shrinkage and porosity inside heavy‑section areas. We produce both integral one‑piece and split‑segment end‑covers. Manufacturing strictly follows customer CAD drawings, 3D models or physical sample references. Material grade will be matched to mill dimension, load magnitude and site running cycle. Critical working surfaces including flange sealing face, bolt hole array and trunnion journal receive precision CNC machining to guarantee concentricity requirement for on‑site erection in mineral concentrator and cement plant projects.

Features

‑ Product Name: Ball Mill End‑Cover / Mill Trunnion Head ‑ Part Category: Heavy‑load main‑structure casting (non‑consumable wear spare‑part) ‑ Compatible Equipment: Ball Mill, AG Mill, SAG Mill, Rod Mill ‑ Material Options: Carbon cast steel, low‑alloy cast steel, Cr‑Mo alloy cast steel ‑ Available Structure: Integral one‑piece / split segmented type ‑ Custom Basis: Customer drawing, 3D file or original sample ‑ Core Performance: Strong anti‑fatigue capacity, stable mechanical performance under repeated alternating heavy load

Technical Parameters

表格

Applications

Our custom‑cast ball mill end‑covers serve large‑scale wet and dry grinding circuits across mineral processing and cement industries.

For metal ore concentrators, feed‑end and discharge‑end trunnion heads sustain continuous alternating stress during 24‑7 mill running. Reliable casting quality prevents structural cracking and avoids costly long‑duration plant shutdowns.

Inside cement production lines, these castings match large tube mills for clinker grinding. Both integral and split‑segment designs are available to suit overflow‑type and grate‑discharge ball mills for copper, gold, iron ore and bulk mineral processing.

Split‑type end‑cover solutions are particularly practical for ultra‑large mill models where integral casting and over‑road transportation become challenging.

Production and Quality Inspection

Casting process simulation is performed prior to smelting to adjust gating‑riser arrangement and reduce shrinkage‑porosity risk within thick‑wall transition fillets. The whole workflow covers simulation, sand preparation, moulding‑core making, mould closing, melting, pouring, controlled slow cooling, shakeout and cleaning, followed by quenching‑and‑tempering heat‑treatment for stress relief and microstructure homogenization.

Each single casting undergoes full‑set multi‑item validation. Heat‑treatment removes residual casting stress and optimises anti‑fatigue property. Hardness testing targets high‑stress fillet transition zones. 3D scanning verifies overall outline and complex flange profile. MT magnetic particle testing focuses on fillet areas to spot surface and near‑surface micro‑cracks. UT ultrasonic testing carries out full‑volume scanning on thick sections to detect internal shrinkage cavity, slag inclusion and voids. Chemical composition analysis validates material compliance. Metallographic analysis evaluates metal matrix status. Large‑size CMM dimensional inspection checks flange flatness, bolt hole positioning and trunnion‑journal concentricity. Final fitting check eliminates assembly obstacles for field erection.

Support and Services

Our engineering team conducts drawing review at early project phase, proposing proper material solution based on mill specification, bearing load and actual operating cycle. Third‑party witness inspection can be arranged on client request; bilingual Chinese‑English inspection documents will be issued for overseas project acceptance.

Full batch production records are preserved for complete traceability. We supply practical technical documents covering on‑site alignment procedure, concentricity calibration and regular inspection points for high‑stress fillet zones, helping operators identify early‑stage fatigue hazards.

Packing and Shipping

Ball mill end‑covers belong to overweight and oversized cast‑machined components. Machined trunnion journal, flange sealing plane and bolt holes need strict protection from impact and rust. Anti‑rust coating is applied on precision‑finished surfaces; cushion blocks protect key functional zones. Heavy‑duty reinforced wooden frames plus steel strapping and waterproof wrapping are adopted for ocean‑going transit.

Each package is clearly marked with PO number, part code, destination, quantity, gross‑net weight and outer dimensions. For overweight / over‑dimension cargo, we formulate dedicated logistics scheme. Our logistics team manages factory loading, document preparation and full shipment tracking until goods safely arrive at destination.