Domestic enterprises involved in the production of slurry pumps and their component manufacturing face a critical decision when it comes to selecting mechanical processing tools. This choice is largely influenced by the fundamental performance characteristics of the products, especially since one of the key features of a slurry pump is its high resistance to fluid flow, making it ideal for transporting abrasive or corrosive slurries. As a result, these pumps are widely used across various industries such as mining, metallurgy, petroleum, coal, transportation, power, construction materials, and municipal engineering projects for tasks like mining, dredging, material transport, concentration, sand removal, ash handling, slime management, and iron ore transport.
Currently, most wear-resistant components of slurry pumps in China are made from high-chromium cast iron. This material has a hardness of approximately HRC 65, which makes it one of the best wear-resistant materials available today. However, due to its complex alloy composition and intricate production process, it has been in use since the 1980s and became more prevalent in the 1990s. Machining this material typically requires cemented carbide cutting tools, which leads to a complicated process, high costs, and low efficiency. This challenge has long been a major issue for many mechanical processing factories.
Ceramic cutting tools represent a new generation of cutting tools in modern metalworking. They are known for their high hardness, strength, red hardness, wear resistance, excellent chemical stability, and low friction coefficient. These properties allow them to process materials that are difficult to machine with conventional tools, while also significantly improving productivity.
Several slurry pump manufacturers have already tested ceramic cutting tools and found that they can effectively address the machining challenges of high-chromium cast iron. Not only do they reduce production costs, but they also greatly enhance production efficiency. Wear parts of slurry pumps typically include components such as the casing (impeller), guard plates (front and rear), impellers, secondary impellers, and vacuum caps. Each of these parts presents unique machining challenges, and the following analysis outlines the different approaches:
First, using traditional tooling:
Processing Technology: Casting - Annealing - Cutting - Quenching
Brief Analysis: This method involves two heat treatment stages, resulting in a long production cycle and high costs. The guard plate and casing require annealing before processing, which limits the cutting speed and leads to very low production efficiency.
Second, using ceramic cutting tools:
Processing Technology: Casting - Cutting
Brief Analysis: This approach eliminates the need for two heat treatment processes, significantly reducing energy consumption and shortening the production cycle. With ceramic tools, roughing and finishing can be done directly after annealing, saving energy and enabling high-speed cutting. This not only improves efficiency but also allows for higher output with the same equipment or reduces the number of machines needed.
Currently, there are numerous domestic manufacturers producing ceramic cutting tools, offering a wide range of materials and varying performance levels. Selecting the right ceramic cutting tool for machining high-chromium cast iron is crucial. A poor choice may hinder the adoption of ceramic tools, disrupt production, and damage confidence in their effectiveness. Companies that continue to rely on traditional methods risk slowing down their development and falling behind in an increasingly competitive market.
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