This study attempts to find optimal conditions of the friction coefficient using a discrete element method (DEM) simulation with various friction coefficient conditions and three different grinding media with various ball sizes in a traditional ball mill (TBM). Using ball motion of the DEM simulation are obtained using the optimal friction coefficient compared with actual motion; photographs are taken by the digital camera and the snapshot images are analyzed. In the simulation, the rotation speed of the mill, the materials and velocity of the grinding media, and the friction coefficient between the balls and the wall of the pot are fixed as the actual experimental conditions. We observe the velocity according to the friction coefficient from the DEM simulation. The friction coefficient is found to increase with the velocity. Milling experiments using a traditional ball mill with the same experimental conditions as those of the DEM simulation are conducted to verify the simulated results. In addition, particle morphology change of copper powder is investigated and analyzed using scanning electron microscopy (SEM) for the milling experiment.

The purpose of this study is to prepare WO3 nanopowders by high-energy milling in mixture gas (7 % H2+Ar) with various milling times (10, 30, and 60 min). The phase transformation, particle size and light absorption properties of WO3 nanopowders during reduction via high-energy milling are studied. It is found that the particle size of the WO3 decreases from about 30 μm to 20 nm, and the grain size of WO3 decreases rapidly with increasing milling time. Furthermore, the surface of the particles due to the pulverization process is observed to change to an amorphous structure. UV/Vis spectrophotometry shows that WO3 powder with increasing milling times (10, 30, 60 min) effectively extends the light absorption properties to the visible region. WO3 powder changes from yellow to gray and can be seen as a phenomenon in which the progress of the color changes to blue. The characterization of WO3 is performed by high resolution X-ray diffractometry, Field emission scanning electron microscopy, Transmission electron microscopy, UV/Vis spectrophotometry and Particle size analysis.

We report the structural, morphological and magnetic properties of the Ni70Mn30 alloy prepared by Planetary Ball Mill method. Keeping the milling time constant for 30 h, the effect of different ball milling speeds on the synthesis and magnetic properties of the samples was thoroughly investigated. A remarkable variation in the morphology and average particle size was observed with the increase in milling speed. For the samples ball milled at 200 and 300 rpm, the average particle size and hence magnetization were decreased due to the increased lattice strain, distortion and surface effects which became prominent due to the increase in the thickness of the outer magnetically dead layer. For the samples ball milled at 400, 500 and 600 rpm however, the average particle size and hence magnetization were increased. This increased magnetization was attributed to the reduced surface area to volume ratio that ultimately led to the enhanced ferromagnetic interactions. The maximum saturation magnetization (75 emu/g at 1 T applied field) observed for the sample ball milled at 600 rpm and the low value of coercivity makes this material useful as soft magnetic material.

Milled carbon fiber (mCF) was prepared by a ball milling process, and X-ray diffraction (XRD) diffractograms were obtained by a 2θ continuous scanning analysis to study mCF crystallinity as a function of milling time. The raw material for the mCF was polyacrylonitrile- based carbon fiber (T700). As the milling time increased, the mean particle size of the mCF consistently decreased, reaching 1.826 μm at a milling time of 18 h. The XRD analysis showed that, as the milling time increased, the fraction of the crystalline carbon decreased, while the fraction of the amorphous carbon increased. The (002) peak became asymmetric before and after milling as the left side of the peak showed an increasingly gentle slope. For analysis, the asymmetric (002) peak was deconvoluted into two peaks, less-developed crystalline carbon (LDCC) and more-developed crystalline carbon. In both peaks, Lc decreased and d002 increased, but no significant change was observed after 6 h of milling time. In addition, the fraction of LDCC increased. As the milling continued, the mCF became more amorphous, possibly due to damage to the crystal lattices by the milling.

A Nanosized WO3 and CuO powder mixture is prepared using novel high-energy ball milling in a bead mill to obtain a W-Cu nanocomposite powder, and the effect of milling time on the structural characteristics of WO3-CuO powder mixtures is investigated. The results show that the ball-milled WO3-CuO powder mixture reaches at steady state after 10 h milling, characterized by the uniform and narrow particle size distribution with primary crystalline sizes below 50 nm, a specific surface area of 37 m2/g, and powder mean particle size (D50) of 0.57 μm. The WO3-CuO powder mixtures milled for 10 h are heat-treated at different temperatures in H2 atmosphere to produce W-Cu powder. The XRD results shows that both the WO3 and CuO phases can be reduced to W and Cu phases at temperatures over 700oC. The reduced W-Cu nanocomposite powder exhibits excellent sinterability, and the ultrafine W-Cu composite can be obtained by the Cu liquid phase sintering process.

Particle morphology change and different experimental condition analysis during composite fabrication process by traditional ball milling with discrete element method (DEM) simulation were investigated. A simulation of the three dimensional motion of balls in a traditional ball mill for research on the grinding mechanism was carried out by DEM simulation. We studied the motion of the balls, the ball behavior energy and velocity; the forces acting on the balls were calculated using traditional ball milling as simulated by DEM. The effect of the operational variables such as the rotational speed, ball material and size on the flow velocity, collision force and total impact energy were analyzed. The results showed that increased rotation speed with interaction impact energy between balls and balls, balls and pots and walls and balls. The rotation speed increases with an increase of the impact energy. Experiments were conducted to quantify the grinding performance under the same conditions. Furthermore, the results showed that ball motion affects the particle morphology, which changed from irregular type to plate type with increasing rotation speed. The evolution was also found to depend on the impact energy increase of the grinding media. These findings are useful to understand and optimize the particle motion and grinding behavior of traditional ball mills.

Fe-TiC composite powders are fabricated by planetary ball mill processing. Two kinds of powder mixtures are prepared from the starting materials of (a) (Fe, TiC) powders and (b) (Fe, TiH2, Carbon) powders. Milling speed (300, 500 and 700 rpm) and time (1, 2, and 3 h) are varied. For (Fe, TiH2, Carbon) powders, an in situ reaction synthesis of TiC after the planetary ball mill processing is added to obtain a homogeneous distribution of ultrafine TiC particulates in Fe matrix. Powder characteristics such as particle size, size distribution, shape, and mixing homogeneity are investigated. In case of (Fe, TiC) powder many coarse TiC particulates with size of several μm are unevenly distributed in Fe-matrix. The composite powder prepared from (Fe, TiH2, C) powder mixture showed a homogeneous dispersion of ulatrafine TiC particulates.

The study of grinding behavior characteristics on aluminum powders and carbon nano tubes (CNTs) has recently gained scientific interest due to their useful effect in enhancing advanced nano materials and components, which significantly improves the property of new mechatronics integrated materials and components. We performed a series of dry grinding experiments using a planetary ball mill to systematically investigate the grinding behavior during Al/CNTs nano composite fabrication. This study focused on a comparative study of the various experimental conditions at several variations of rotation speeds, grinding time and with and without CNTs. The results were monitored for the particle size distribution, median diameter, crystal structure from XRD pattern and particle morphology at a given grinding time. It was observed that pure aluminum powders agglomerated with low rotation speed and completely enhanced powder agglomeration. However, Al/CNTs composites were achieved at maximum experiment conditions (350 rpm, 60 min.) of this study by a mechanical alloy process for Al/CNTs mixed powders because the grinding behavior of Al/CNTs composite powder was affected by addition of CNTs. Indeed, the powder morphology and crystal size of the composite powders changed more by an increase of grinding time and rotation speed.

[ WO3 ]powders were ball-milled with an alumina ball for 0-72 hours. In2O3 doped WO3 was prepared by soaking ball-milled WO3 in an InCl3 solution. The mixed powder was annealed at 700˚C for 30 min in an air atmosphere. A paste for screen-printing the thick film was prepared by mixing the WO3:In2O3 powders with α-terpinol and glycerol. In2O3 doped WO3 thick films were fabricated into a gas sensor by a screen-printing method on alumina substrates. The structural properties of the WO3:InO3 thick films were a monoclinic phase with a (002) dominant orientation. The particle size of the WO3:InO3 decreased with the ball-milling time. The sensing characteristics of the In2O3 doped WO3 were investigated by measuring the electrical resistance of each sensor in the test-box. The highest sensitivity to 5 ppm CH4 gas and 5 ppm CH3CH2CH3 gas was observed in the ball-milled WO3:InO3 gas sensors at 48 hours. The response time of WO3:In2O3 gas sensors was 7 seconds and recovery time was 9 seconds for the methane gas.

Mechanical coating process was applied to form 89 %-hydrolyzed poly vinyl alcohol (PVA) onto boron carbide (B4C) nanopowder using one step high energy ball mill method. The polymer layer coated on the surface of B4C was changed to glass-like phase. The average particle size of core/shell structured B4C/PVA was about 50 nm. The core/shell structured B4C/PVA was formed by dry milling. However, the hydrolyzed PVA of 98~99% with high glass transition temperature (Tg) was rarely coated on the powder. The Tg of polymer materials was one of keys for guest polymer coating on to the host powder by solvent free milling.

유성밀로써 사문석과 활석을 분쇄시 X-ray 회절분석, FT-IR, DSC-TG, 입도분석 그리고 SEM관찰 등을 이용하여 결정조직과 물리적 특성변화를 조사하였다. 분쇄기간이 증가함에 따라 사문석과 활석 원시료의 결정피크가 점처 감소하여 120분 이상 분쇄시 비정질상으로 변하였으며 이와 같은 변화는 마그네슘 결정 조직의 무질서에 기인한다. 분쇄된 시료에서 나타나는 흡열반응의 피크는 원시료보다 낮은 온도에서 관찰되었다. 또한 불규칙한 모양의 원시료는 분쇄처리를 실시함에 따라 구형의 응집체로 변하였다.

회전 불밀에 있어서 볼의 운동을 비선형 spring과 비선형 deshpot로 구성된 Kelvin모델을 사용한 DEM(Distinct Element Method;개별요소법)에 의하여 2차원으로 해석하였다. 모델에 있어서 점성계수는 볼과 밀벽사이의 반발실험 데이타로 부터 결정하였다. 각볼의 동적인 운동은 비선형 점탄성과 Newton의 운동법칙를 기초로하여 모사되었다. 밀이 회전하는 동안 볼의 궤적과 동적인 운동은 실제 실험에 의한 밀내에서의 볼의 운동고 잘 일치하였다. 본 연구에서 제안된 모델 시뮬레이션은 회전 볼밀내의 실제의 3차원인 볼의 운동에 대한 해석에 중요한 단서가 될 수 있었다. 볼의 운동고 운동에너지는 회전 볼밀의 속도와 볼의 충진율에 의해 크게 영향을 받았다.