Engineered Ball Mill Journal Refurbishment with Rotating External Machining System
Worn-out Ball Mill Journal Required Engineered Refurbishment Solution
Category: Cement & Mining
Method(s) Used: On-Site Machining
Location: Illinois
IPM was contacted to refurbish a worn feed-end journal on a 14-foot ball mill. The repair required machining a large bearing surface without ball mill rotation while working within a very limited space inside the plant and a tight outage schedule. To meet these challenges, IPM engineered a custom rotating external machining system that fits within the space available and enables in-place machining and polishing, restoring the journal surface and meeting the customer’s outage schedule.
Project Documentation
14 ft. ball mill requiring repair
Before – Worn ball mill journal
After – Restored journal surface
Journal refurbishment with engineered rotating external machining system
Ball Mill Journal Refurbishment without mill rotation
The feed-end journal on a 14-foot ball mill was severely worn and required machining to restore the bearing surface and extend its operability. IPM engineered a rotating external machining system to perform precision in-place machining without rotating the mill itself. The project included pre- and post-machining inspections, precision alignment, controlled material removal, and final polishing of the journal. The IPM solutions restored the bearing surface to the customer’s expectations without the need for major disassembly of the ball mill.
Engineered Solution to Demanding Requirements
Refurbishing a journal of this magnitude presented several challenges, including constrained site conditions, limited machining clearances, strict material removal requirements, and the need to establish a precise alignment reference for accurate machining.
To overcome these challenges, IPM engineered and manufactured custom split tooling rings that mounted directly to the journal and referenced unworn surfaces adjacent to the repair area. The rings were carefully installed, aligned, and verified using indicator readings and straightness checks to establish a precise machining platform. With this system in place, IPM performed precision on-site machining while removing only the minimum material required to restore the journal to the specified dimensions and surface finish.
Restored Ball Mill Performance
The ball mill journal surface was successfully restored to a serviceable condition through precision machining using an engineered rotating external machining system. Final inspections verified that the restored journal met all customer requirements for size and surface finish. By eliminating the need for ball mill rotation and major disassembly, IPM reduced outage time and avoided the costs and logistical challenges associated with conventional repair methods.
Contact IPM today at 414.667.6259 or visit our Cement & Mining Page to see how Cement Manufacturing Facilities worldwide depend on In-Place Machining Company to perform the most demanding, high-tolerance, precision field machining projects.
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