The crushing and milling method uses equipment like jaw crushers and ball mills to break down brittle metals into fine powder. Ball mills work by rotating a cylindrical vessel with grinding media like steel balls inside to impact and fracture metal particles down to a fine size. The main objectives of milling are particle size reduction and modification of material properties through processes like micro forging and fracture. Different types of mills are suited for various applications depending on needed particle size and material properties.

1. Crushing and Milling Method to form Powder

2. Manufacturing of Metal Powders
Some of the important methods are:
1. Atomization
2. Machining
3. Crushing and Milling
4. Reduction
5. Electrolytic Deposition
6. Shotting
7. Condensation

3.  Used for brittle materials.
 Jaw crushers, stamping mills,
ball mills - used to breakdown
the metals.
 In earlier stages of powder
preparation gyratory crushers
are used.
 For fine powder, the metal particles
are fractured by impact.

4. Main objective of milling
• Particle size reduction (main purpose),
• shape change ,
• solid state alloying,
• mechanical or solid state mixing,
• modification of material properties.

5. 1. Micro forging : Individual particles or group of
particles are impacted repeatedly so that they flatten
with very less change in mass
2. Fracture : Individual particles deform and cracks
initiate and propagate resulting in fracture
3. Agglomeration : Mechanical interlocking due to
atomic bonding or vander Waals forces.
4. Deagglomeration : Breaking of agglomerates.

6. Milling equipment:
are generally classified
as crushers & mills.

7. Ball mills
•Contains cylindrical vessel rotating horizontally along the axis.
•The vessel is charged with the grinding media(hardened steel, or tungsten
carbide, porcelain, alumina).
Important Parameters:
1. An optimum/critical speed is adjusted
for maximum impact velocity.
2. The size and density of the milling
medium is selected according to the
deformation and fracture resistance for
metals.

8. Vibratory ball mill
 High amount of energy is imparted to the particles
Milling being accelerated by vibrating the container.
 Vibration frequency - 1500 to 3000 oscillations/min.
 Amplitude of oscillations - 2 to 3 mm.
The grinding bodies is made of steel or carbide balls, that are 10-20
mm in diameter.
The mass of the balls is 8-10 times the charged particles.

9. Attrition mill
 The charge is ground to fine size by the action of a vertical shaft with side
arms attached to it.
 The ball to charge ratio may be 5:1, 10:1, 15:1.
 More efficient in achieving fine particle size.
 In these mills the rotational speeds are nearly 6 – 80 rpm while the size of
medium (balls) used is 3 – 6 mm.

10. Fluid energy grinding or Jet milling:
The fluid used is either air about 0.7 Mpa
or stream at 2 Mpa
 The pressurized fluid is introduced into the
grinding zone through specially
designed nozzles which convert the
applied pressure to kinetic energy.

11. Rod mills
Horizontal rods are used instead of balls to grind.
Granularity of the discharge material is 40-100 mm.
The mill speed varies from 12 to 30 rpm.

12. 1. Rubbing action causes contamination of powder
since balls may also get rubbed.
2. There is a possibility of excessive oxidation of
final powder.
3. Quality of powder is poor.
4. Agglomeration may take place.