Regarding industrial production methods of grinding media (balls), there are two main methods, casting method and extrusion method. The main factors in media selection is the alloy and diameter of the grinding media. However, other factors affect the performance of grinding media.
Please comment on which factors (reasons) cause milling media failure? And, how can be prevented?
In this case, the destruction of the balls was not due to some particularly difficult operating conditions, but because of the initial defects of the balls themselves (cavitys, cracks, etc.). From the photos, your grinding balls are of extremely poor quality. There can be a lot of reasons for poor quality, but they all indicate a violation of the production technology committed by the company that manufactures these products. My advice is to change supplier or buy more expensive grinding balls.
There are two types of milling balls: 1) forging and 2) casting.
Forging balls are for break minerals and casting balls for grind up concrete.
In the first process you need a good balance between volumetric hardness and toughness because minerals are too hards.
As concrete is very soft, it is enough to grind it with casting balls.
I think that you could obtain excellent information by means of the following paper:
Grinding media quality assurance for the comminution of gold ores
J.S. MOEMA, M.J. PAPO, G.A. SLABBERT and J. ZIMBA
I work many time testing forging balls: volumetric hardness (wear resistance of the ball), drop ball test (toughness of the ball), and wear/break in service conditions.
From my point of view the balls of the photos are casting balls. This type of balls, normally, are of low quality (low toughness and low wear resistance).
Best regards.
Another excellent work is:
Evaluation of commercial US grinding balls by laboratory impact and abrasion tests by R. Blickensderfer and J. H. Tylczak
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