Custom Wear Rings for Cement Mills

Case Study: Custom Wear Rings for Cement Mills – Precision Engineering for Enhanced Durability

At CAFU Machinery, we specialize in delivering high-performance cement plant parts designed to withstand the extreme demands of cement production. This case study highlights our expertise in precision machining & fabrication, focusing on custom wear rings for a cement plant’s grinding mill. With stringent requirements for material quality and dimensional accuracy, this project exemplifies our ability to solve complex challenges in machining services.

Client Challenge: Replacing Critical Seal Components

Client Profile:

• Industry: Cement Plant

• Location: South East Asia

• Objective: Replace worn-out seal rings

Technical Requirements:

• Material: NM450 wear-resistant steel (Brinell hardness: 450 HBW)

• Dimensions: 1,200mm diameter × 13mm thickness

• Surface Finish: Ra 1.6μm (mirror-grade precision)

• Flatness Tolerance: ≤0.1mm across the entire surface

CAFU’s Engineering Solution

1. Material Selection & Preparation

NM450 Steel Advantages:

• 3x higher abrasion resistance vs. standard AR400 plates

• Impact toughness: ≥50 J/cm² at -20°C (EN 10045-1)

Laser Cutting:

12kW fiber laser cut 15mm NM450 plates to 1,200mm blanks (±0.5mm tolerance)

2. Precision Machining Process

Step 1: Rough Turning

• Lathe: 1.5m CNC vertical lathe with hydraulic steady rests

• Operations: Reduced thickness from 15mm to 13.5mm

Step 2: Drilling

• 12×Φ14mm bolt holes

• Positional accuracy: ±0.1mm

Step 3: Finish Grinding

• Surface grinding machine with diamond abrasives

• Achieved Ra 1.6μm finish and 0.08mm flatness

Technical Challenges & Innovations

Challenge 1: Preventing Distortion in Thin, Large-Diameter Parts

Solution:

• Multi-step clamping with customized fixtures

Challenge 2: Maintaining Hardness During Machining

Solution:

• Reduce the feed depth of each grind and cool the workpiece sufficiently and uniformly

• Post-machining hardness verification (445–455 HBW)

Challenge 3: Handling Oversized Components

Solution:

• Custom rotary workholding system for 1.2m rings

• Increase workpiece temperature control and measurement frequency

Quality Assurance Protocol

• Dimensional Checks: 3D laser scanning vs. CAD model

• Surface Roughness: Ripple Gauge

• Certification: Material test certificates

Why Choose CAFU for Cement Plant Parts?

• NM400 to NM500 Wear Plates

• Custom Precision Machining & Fabrication

• Large-Part Machining Capacity

• End-to-End Services: Reverse engineering of worn components

Applications of Custom Wear Rings

• Cement mill seal assemblies

• Rotary kiln tire seats

• Crusher rotor protection rings

Upgrade Your Wear Parts Now

Whether you are an experienced purchasing professional in the cement industry or a member of a specialized maintenance team in the mining industry, contact the CAFU service team and we will provide you with cost-effective and reliable wear parts solutions.