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A novel two-disc cross rolling process for manufacturing large-diameter grinding balls: A numerical comparison with conventional rolling methods
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1
Lublin University of Technology
 
2
2Ningbo University, Fenghua Rd. No.818, 314211 Ningbo, China
 
 
Publication date: 2026-08-19
 
 
Corresponding author
Zbigniew Pater   

Lublin University of Technology
 
 
Adv. Sci. Technol. Res. J. 2026; 20(12)
 
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ABSTRACT
The production of large-diameter steel grinding balls remains a significant technological challenge due to high forming loads and the need for large, specialized rolling mills. This study introduces a novel two-disc cross-rolling (TDCR) process and evaluates its technological potential through a numerical comparison with conventional cross-wedge rolling (CWR) and skew rolling (SR). Finite element simulations using Forge software were performed to analyze the forming of C60 steel balls with a diameter of 125 mm. The comparison included temperature and strain distributions, dimensional accuracy, forming loads, energy consumption, drive power requirements, and production efficiency. The results showed that all analyzed methods enabled the production of balls meeting industrial requirements. The highest dimensional accuracy was obtained in the TDCR process due to final calibration in the disc tools. Moreover, TDCR generated the lowest radial load (366 kN), compared with 677 kN for SR and 1419 kN for CWR, and required the lowest drive power (2 × 54.6 kW). Although its specific energy consumption was higher than that of CWR, the higher final ball temperature suggests the potential to reduce billet heating energy. The results confirm that TDCR is a promising alternative to conventional large-diameter ball rolling technologies.
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