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156 Huynh Xuan Khoa, Sunwoo Bae, Sangwon Bae, Byeong-woo Kim, and Ji Soon Kim
Journal of Korean Powder Metallurgy Institute (J. Kor. Powd. Met. Inst.)
Planetary Ball Mill Process in Aspect of Milling Energy 157
mill were calculated in order to predict the operative mining the criterion for the detachment of ball from the
modes of a planetary ball mill. The angular velocity ratio rotating vial wall prior to impact, so that the detachment
(R, a ratio of rotation speed of the vial and revolution angle never assumes an unrealistic value in the subse-
speed of the disk) is useful in the description of the kinet- quent analysis.
ics of the mill. Based on the calculation of the move- Recently, Mio et al. [22-24] performed a set of experi-
ment of a ball, they indicated that three different types of ments to study effects of the rotational direction of a pot
trajectory are possible. These three different milling in a planetary ball mill and its speed ratio against revolu-
modes appear when the ratio of the milling velocities is tion of a disk on the specific impact energy of balls cal-
modified and are termed chaotic (pure impact) for R < culated from the simulation on the basis of the Discrete
Rlimit, impact + friction for Rlimit < R < Rcritical and fric- Element Method (DEM). The specific impact energy
tion for R > Rlimit. The study suggested that a mill could be increases with an increase in the rotation-to-revolution
designed for specific purposes depending upon the value speed ratio in the initial stage and then falls around the
of R. Pure impact is obtained for R = 2.25, whereas high critical speed ratio, which can be calculated by the bal-
friction results from values close to Rcritical. ance Eq. based on the centrifugal forces acting on a ball
Gaffet [8-10] suggested through more rigorous analy- due to the combination of the rotation and revolution. The
ses that the power of ball impact rather than the kinetic highest value in the specific impact energy of balls dur-
energy or frequency might determine the characteristics ing milling could be achieved effectively around this criti-
of end products and the efficiency of the milling process. cal speed. This critical speed would, therefore, be a key
These models, however, overlooked some important kine- condition in milling for designing suitable and optimum
matic parameters like the angular variation of impact mechanical milling performance. The scale-up method for
velocity in determining the effective amount of power/ the planetary mill was also established by evaluating the
energy transferred to the powder particles during a given impact energy. The impact energy is proportional to the
collision event. In this regard, Besset et al. [11] pro- cube of the diameter of the pot, the depth of the pot and
posed that the impact velocity might be experimentally the revolution radius of the disk, respectively. When the
determined from the size of indentation on a metallic sur- planetary mill is scaled-up in geometrical similarity, the
face. Magini and Iasonna [12], Iasonna and Magini [13] impact energy of the balls is proportional to 4.87 power of
and Magini et al. [14] considered the same kinematic the scale-up ratio. Lu et al. [25], based on the kinematics
conditions proposed by Burgio et al. [1], and calculated of ball motion, described the collision frequency and
the energy transferred per impact to compare the latter power. They derived the normal impact forces and the
with the experimentally determined electrical/mechanical effective power from analysis of collision geometry. The
power consumed. In spite of such an elegant approach, impact angle of the milling ball ranged from 90 to 0 with
the analysis did not yield an optimum condition of mill- the variation in the angular velocity ratio. The ideal val-
ing in terms of power/energy for a given mechanical ues of the normal impact force and tangential force could
alloying condition. Watanabe et al. [15] simulated the be obtained. When the dynamic parameters of the plane-
kinematics and related them with the trajectory of ball tary ball mill were given, the highest impact energy could
motion for a various ball mill devices using Kelvins be obtained for the optimal value of angular velocity ratio.
dashpot-spring model. The analysis as well as the photo- The optimal ratio was found to be 1.15 at 800 rpm.
graphic observation of ball trajectory suggested that the
relative direction of rotation between the disk and vial 4. Processing Variables in Planetary
(i.e. parallel and counter rotation) determines the nature Ball Mill Process
of ball trajectory, i.e. cataracting and cascading motion,
respectively. Chattopadhyay et al. [21] presented a kine- The planetary ball mill process involves loading of the
matic analysis in terms of a single Cartesian reference powder particles with the grinding medium in a con-
frame for both the rotating disk and vial. The model tainer and subjecting them to heavy deformation. Process-
explicitly defined the role of milling parameters in deter- ing variables can be divided in three groups as follows:
5. Correlation of Processing Variables with the where Kc = (1/2)Ka Kb2; mb [kg], Wp [rpm = 2/60 rads/
Milling Energy sec.], Rp [m]
The analysis of the collision previously described allows
5.1. Determination of the absolute velocity(vb) and to assume that the Eq. (4) really represent the energy given
the kinetic energy of a single ball to the powder in a real milling process, at least as long as
As illustrated in Fig. 2, the powder is ground by two the collision is considered to be in elastic.
Journal of Korean Powder Metallurgy Institute (J. Kor. Powd. Met. Inst.)
Planetary Ball Mill Process in Aspect of Milling Energy 159
b = (1 nve)
end-products [20].
The energy map of Fig. 5(a) shows a predictive capa-
bility for any experiment carried out on the Pd-Si system
in any milling condition. The continuous lines are E/
Qmax - dbWp relationship of Eq. (6) with db from 1.5 to
8.0 mm. A threshold value of 50 J/ghit separates the
energy map into two regions. Milling with energy above
the threshold, amorphous phase was formed, but below
this value only intermetallic phase could be found.
Liu and Magini [26] also established the milling map
for mechanical alloying of Mo-Si system as shown in
Fig. 5(b). The map reveals that in case of milling with the Fig. 6. Milling map showing the Pe-nv relationship with typical
planetary mill rotation speeds [14].
lowest energy input, Condition A, no reaction occurred. By
increasing milling energy from Condition B to E, inter-
metallic compounds with different phases were formed. ing coefficient of the Nb balls, b, has to be considered in
According to the XRD results, the high temperature calculating the power consumption.
phase -MoSi2 was formed as milling with lower mill-
Pcal = bEft
ing energy (B to D conditions), while the low temperature
Pcal = P*bmbWp3Rp2Nb, [W] (9)
phase -MoSi2 was mainly included in the end product
with the highest milling energy. with P* includes (1/2)KaKbKv
Eq. (9) is the power consumption during milling predicted
5.3. Power consumption by the collision model. It can help to set up the suitable
The Eq. (4) gives the energy transferred to the powder milling condition in order to obtain a desired end prod-
during a single collision event. Multiplying this energy uct.
by the number of events per unit time, i.e., by the fre- Fig. 6 shows the power absorption as a function of the
quency of the hits, we obtain the power absorption. The filling of the vial and the rotation speeds of the planetary
collision frequency, f, for a single ball can be written as mill [14]. The power values on the vertical axis indi-
follows [1]. cated by dots are the measured values for typical rota-
tion speeds. It can be seen from Fig. 6 that three different
f = K (Wp Wv)/2 = KkWp = KvWp (7)
efficiency regions exist. In the first region(A) the power
The value of K depends upon the ball diameter and can consumption increases linearly with the filling up to
be evaluated to be approximately 1.5 for ball diameters about nv 0.18 (arrow). In this region there is no recipro-
of 8-10 mm. The k is the kinetic factor, the ratio of Wv/ cal hindering of the balls, the yield coefficient b is
Wp, that is 1.15 and 1.65 for the Fritsch Pulverisette 5 nearly 1. When nv > 0.18, the P-nv relation deviates from
and AGO-2, respectively. In the experiments that the linearity (region B). This means that above a certain level
vials were filled at a low level, the reciprocal hindering of filling, the balls hinder each other and thereby the
of the Nb balls is negligible and the total collision fre- energy transfer process becomes less effective than
quency ft is given by expected (b < 1). In other words the efficiency with respect
to the charge decreases. Beyond the peak (nv 0.5 ) , the
ft = fNb
power consumption decreases in absolute value, region
The calculated power consumption is thus given by C, and tends towards zero (b = 0).
The horizontal dash-line shows equi-power consump-
Pcal = Eft
tion. On this line, the power consumption is constant for
Pcal = (1/2) KaKbKv mbWp3Rp2Nb (8)
any different nv and Wp. Due to the constant power con-
If vial were filled at a high level, the reciprocal hinder- sumption, it is expected that the same end product might
Journal of Korean Powder Metallurgy Institute (J. Kor. Powd. Met. Inst.)
Planetary Ball Mill Process in Aspect of Milling Energy 161
Journal of Korean Powder Metallurgy Institute (J. Kor. Powd. Met. Inst.)
Planetary Ball Mill Process in Aspect of Milling Energy 163
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[17] http://www.retsch.com/products/
was in good agreement with the result from the measure-
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Journal of Korean Powder Metallurgy Institute (J. Kor. Powd. Met. Inst.)