Custom Fabrication of Ball Mill Components
Heavy-Duty Precision Engineering for Grinding Systems
Openex offers custom fabrication of large-scale ball mill components tailored to the mining and mineral processing industries. With advanced machining capabilities and deep industry experience, we handle complex structural parts like mill cylinders, flanges, and bearing housings — all built to withstand extreme load, vibration, and wear.
Our facility supports fabrications with diameters up to 15 meters and heights of 5 meters. These fabrication require both robust welding craftsmanship and micron-level machining precision — challenges that we’re equipped to meet.
What We Fabricate
- Ball mill shell cylinders (wall thickness up to 83 mm)
- Segmented flanges and bolted ring joints (up to 190 mm welding thickness)
- Feed end and discharge end assemblies
- Bearing housings and trunnion structures
- Internal wear liners and support components
Material & Construction
Our standard material for mill shells is Q235B structural steel, processed through multiple fabrication steps:
- Plate cutting & beveling
- Rolling & forming to curvature
- Welding & sub-assembly
- Heat treatment for stress relief
- Precision machining
- Surface finishing (painting, lining)
Machining Capabilities
Openex operates large-scale, high-precision machining equipment to meet the exacting tolerances required by OEMs and EPCs.
Featured Equipment:
- Innse-Berardi 280 Floor Borer: For machining flange faces with verticality ≤ 0.05 mm
- 22-Meter Vertical Lathe: Supports full turning and hole drilling of massive mill shells
- Multi-axis CNC drilling systems: For complex bolt-hole patterns and radial hole arrays
- Custom fixtures & jigs: Used to maintain concentricity and minimize distortion
Key Specifications
| Parameter | Value |
|---|---|
| Max Cylinder Diameter | 15,000 mm |
| Max Cylinder Height | 5,000 mm |
| Wall Thickness | Up to 83 mm |
| Flange Verticality | ≤ 0.05 mm |
| Runout Tolerance | ≤ 0.05 mm |
| Surface Roughness | ≤ 3.2 µm |
| Hole Position Accuracy | Controlled within 0.05 mm across entire face |
Engineering Challenges & Solutions
Manufacturing segmented ball mill shells is a complex task that pushes the limits of forming and machining. We overcame challenges in:
- Precision Hole Drilling: Multi-axis heads allowed perfect alignment of closely spaced bolt holes
- Thermal Stability: Controlled feed rates and step machining minimized heat distortion
- Runout Control: On-machine measurement and real-time adjustments ensured concentricity
- Weight Management: Components over 90 tons handled using custom supports and safety protocols
Inspection & Quality Assurance
Every component undergoes comprehensive QA using:
- Coordinate Measuring Machine (CMM) inspection
- Ultrasonic testing (UT) of weld seams
- Dimensional verification with laser tracking systems
- Surface finish analysis and hardness testing
Request a Quote
Have a custom ball mill component project? Our team is ready to engineer, fabricate, and deliver exactly what you need.
📧 Email: [email protected]
📞 Call: +86 186 5928 0806
Our Full-Service Metal Fabrication: metal cutting and sheering, metal forming, bending, and rolling, welding, CNC machining, sheet metal assembly, and quality inspection
Machining Services: Multi-Axis Machining, 5-Axis Machining, CNC Milling | Vertical and Horizontal, CNC Turning | Vertical and Horizontal, CNC Engineering, CMM Inspection
Material Types: castings, forgings, fabricated weldments, billets, bar stock, and plate
Metal Materials we worked: Stainless steel, Carbon Steel, aluminum, brass, bronze, chromium, copper, Monel, nickel, titanium, zinc, and many other superalloys.
Certifications: ISO 9001, CE EN 1090-1, ISO 3834, ABS, AWS, API, ASME, DNV.GL.
Industries Served: Mining, Construction, Oil & Gas, Power Generation, Marine, Automotive, Renewable Energy, Pulp & Paper, Bridge, Aerospace, Defense, Printing and Dyeing, Machinery, etc.