Optimization of the high energy ball-milling: Modeling and parametric study

• It has been investigated the effect of not so discussed milling parameters on the milling efficiency
• The effects of the milling parameters on the performance of the mill are simultaneously investigated
• The weight loss of the powder can greatly enhance the performance of milling
• The excessive rise in the ball size distribution is associated with adverse outcomes in efficiency
• The balls made of WC compared to those of Si3N4 and steel have a more positive effect on efficiency

In the present study, the effect of not so much discussed milling parameters such as vial to plate spinning rate, ball size distribution and type of balls on the performance (energy) of the high energy ball milling has been investigated for the first time. Furthermore, different scenarios that lead to an increase in the BPR such as the powder weight loss, the increase of diameter and the number of balls are analyzed and their effects on the efficiency of the milling are discussed. The important point is that contrary to the previous studies in which the milling parameters were independently investigated, in this research the effects of the milling parameters on the performance of the mill are simultaneously investigated. The results showed that the powder weight loss can greatly enhance the performance of milling, while the increase of the number of balls at high BPR ratio, has a quite negative effect on the milling performance. Besides, excessive rise in the ball size distribution is associated with adverse outcomes in the milling efficiency, especially when the number of balls increases. Furthermore, the balls made of tungsten carbide compared to those of silicon nitride and steel have a more positive effect on the milling efficiency especially when the weight of powder is reduced. A mathematical model is also introduced to analyze the effect of milling parameters on the milling energy and the obtained results are compared with the experimental ones. According to the results obtained, if the vial to plate spinning rate is 1.2, the mill has a better performance however, by increasing the diameter of the balls, this ratio is changed to 1.4.

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