How to control the fragmentation rate of Steel Cut Wire Shot (SCWS) is a comprehensive issue that involves material selection, production process, operating parameters and maintenance management. Fragmentation rate is one of the most important indicators for evaluating the performance of Steel Cut Wire Shot, and a high fragmentation rate not only increases the cost, but also affects the cleaning effect and shot blasting efficiency. The following content will start from the analysis of the causes of fragmentation rate, discuss the specific measures to control the fragmentation rate, and combined with practical cases to illustrate its application.

1. Analysis of the causes of fragmentation rate

Steel shot will be subjected to high-intensity repeated impact and friction in the process of use, and the following factors may lead to its fragmentation:

1.1 Raw material quality

The raw material of steel cut shot is usually carbon or Stainless Steel wire, the quality of which directly determines the toughness and durability of the pellets. If the chemical composition of the steel wire is uneven or high in impurities, the pellets are more likely to break when subjected to force.

1.2 Manufacturing process

The manufacturing process of steel cut pellets has an important impact on their shatter resistance:

Cutting accuracy: cut pellets with many edge burrs or irregular shape will form stress concentration points and increase the risk of fragmentation.

Heat treatment process: Improper heat treatment may result in pellets that are too hard or not tough enough, making them more prone to fragmentation during impact.

Surface treatment: Pellets that have not been surface deburred or polished have sharper edges and are more likely to fragment during use.

1.3 Shot Peening Process Parameters

Blasting pressure: too high a pressure will accelerate the wear and tear of the steel cut pills and fragmentation.

Blasting Angle: Unreasonable blasting angles can cause the pellets to repeatedly impact the walls of the equipment or the sharp edges of the workpiece, thus increasing the risk of fragmentation.

Blast Media Circulation: Repeated use of steel shot without filtering the debris will increase the impact and damage to the intact particles from broken particles.

1.4 Workpiece Characteristics

Complex or sharp workpiece surfaces increase the chances of steel shot fragmentation. For example, sharp edges or harder materials will have a stronger impact on the pellets.

1.5 Maintenance of Shot Peening Equipment

Components such as blast wheels, nozzles, etc. within the equipment that are severely worn or improperly adjusted can place additional stress on the steel cut wire pellets, causing them to fragment.

2. Measures to control the fragmentation rate of Steel Cut Wire Shot

2.1 Selection of high quality raw materials

Ensure that the raw materials are chemically homogeneous and low in impurities. High-quality raw materials with high toughness and impact resistance can significantly reduce the risk of splintering.

2.2 Optimise the manufacturing process

Precise cutting: adopt high-precision cutting equipment to ensure that the particle shape of the steel cut shot is uniform and reduce the stress concentration points.

Heat treatment control: Optimise the heat treatment process to achieve the best balance between hardness and toughness of steel cut shot. For example, the hardness is usually controlled between HRC40-50, which ensures the cleaning efficiency and reduces the fragmentation rate.

Deburring and polishing: Remove the burrs on the edge of the pellets by mechanical or chemical methods to ensure a smooth surface to reduce the stress concentration during impact.

2.3 Reasonable setting of shot blasting process parameters

Control of blasting pressure: according to the material of the workpiece and cleaning requirements to choose the appropriate pressure, to avoid excessive pressure resulting in accelerated fragmentation of steel cut pills.

Optimise the spraying angle: adjust the spraying angle, try to make the steel shot contact the workpiece in a smoother path, reduce the number of bounces.

Select the appropriate particle size: select the appropriate size of steel-cutting pellets according to the characteristics of the workpiece, to avoid the extra impact of too large particles on the equipment and the workpiece.

2.4 Improve the circulation system

Installation of filtration devices: Add high-efficiency filters in the circulation system of steel-cutting pills, timely removal of broken particles and dust, to avoid mixing with intact particles.

Regular cleaning of the interior of the equipment: Remove deposits of debris and impurities to reduce wear and tear on the steel-cutting shot.

2.5 Workpiece design optimisation

Where possible, optimise the design of the workpiece to reduce the impact of sharp edges and complex geometrical features on the steel-cutting shot. In addition, appropriate chamfering of workpiece edges can be considered to reduce fragmentation rates.

2.6 Maintenance and care of shot blasting equipment

Check the equipment components: Regularly check the wear and tear of key components such as blast wheels, nozzles and pipelines, and promptly replace parts that are badly worn.

Optimise internal layout: Ensure that the circulation path of the steel-cut shot is as smooth as possible to reduce collisions or blockages.

2.7 Training of operators

The skills and experience of the operator are also critical to the control of the fragmentation rate. Through training, the operators will be able to master the correct method of equipment adjustment and setting parameters of the blasting process.

3. Actual cases and application effects

Case 1: Automotive parts shot peening

In the shot blasting cleaning of automotive engine parts, the use of high-quality