Common Disadvantages of the Steel Ball Light Ball Process

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The steel ball light ball process is widely used in bearing manufacturing, but it can lead to several common disadvantages that affect the quality and performance of the final product. Understanding these issues can help improve production efficiency and reduce defects. 1. **Surface Damage and Bruising**: One of the most common problems occurs when the radius of the entrance of the ball plate does not match the radius of the splitter. This mismatch leads to an uneven surface, causing bruises or dents on the steel balls. The result is a non-smooth finish, which can affect the ball's performance and lifespan. 2. **Eutectic Group Issues**: If the eutectic group on the pitting disc is too large, or if the grooves are too deep, it can cause shrinkage holes to appear on the pebble disk during use. These imperfections can lead to metal particles breaking off and embedding into the outer surface of the steel balls. Additionally, if the number of steel balls entering the two plates is insufficient, the working pressure may not be reduced effectively, leading to improper processing and uneven force distribution on the ball surface. 3. **Cracking Due to Large Ring Blanks**: When the ring blank is too large, high pressure and speed during the process can create stress concentration at specific contact points. This results in microcracks that may not be immediately visible but can be clearly seen after hot pickling. Such cracks significantly weaken the structural integrity of the steel balls. 4. **Turtle Cracks and Loss of Self-Renewal Ability**: The "self-renewing" ability of the turtle crack is lost when the groove on the light sphere disc is not properly maintained. As a result, the outer surface of the steel ball may first show a bright appearance. Over time, as processing continues, the outer surface becomes worn out, and the turtle crack becomes more pronounced, affecting the ball’s durability. To avoid these issues, manufacturers should ensure proper maintenance of the equipment, adjust the parameters carefully, and monitor the process closely. Regular inspections and quality checks are essential for maintaining the integrity and performance of the steel balls.

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