The production of gypsum typically involves several steps, including mining, crushing, grinding, calcination, and drying. Here are the five steps in gypsum production:
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1.Mining: Gypsum is extracted from underground or open-pit mines. In underground mining, shafts or tunnels are dug into the earth to reach the gypsum deposits. Open-pit mining involves the removal of overlying soil and rock to access the gypsum. The extracted gypsum is usually in the form of large chunks or layers.
2.Crushing: The extracted gypsum is transported to a crushing facility where it is crushed into smaller pieces. This crushing process helps to break down the gypsum into manageable sizes and prepare it for further processing.
3.Grinding: The crushed gypsum is then transported to a grinding mill, where it is pulverized into a fine powder. The grinding process involves the use of mechanical forces to break down the gypsum particles and reduce them to a desired fineness. This powdered gypsum is often referred to as land plaster or stucco.
4.Calcination: The ground gypsum powder is subjected to a process called calcination. Calcination involves heating the gypsum at high temperatures (around 150-165 degrees Celsius or 300-350 degrees Fahrenheit) in order to remove the water of crystallization from the gypsum and convert it into a different chemical form known as calcium sulfate hemihydrate, also known as plaster of Paris.
5.Drying: After calcination, the gypsum product is in the form of calcium sulfate hemihydrate, which still contains a small amount of water. The product is dried in a specialized drying chamber or kiln to remove the remaining moisture, resulting in the final product known as commercial gypsum or drywall gypsum.
It's worth noting that the specific production processes may vary depending on the equipment and technology used by different gypsum manufacturers.
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Looking good!
My only concern with milling plaster products would be rapid dulling of the bits. (I don&#;t know how abrasive it would be but I am assuming it is grater than wood?) But this is easily addressed by having a separate set of bits for plaster work.
Back when I first got into CNC I played around with making plaster molds for metal casting.
I would carve the master in blue jeweler&#;s wax, make a silicone mold, cast it in plaster, pour molten metal in that. (I used low a low melt casting metal I got from micromark (expensive) and silver plumber&#;s solder, heated with a propane torch.)
It worked, ok. Most of my attempts were flawed in some way. I had a lot to learn about mold design, optimizing the shape for metal casting, adding sprues and pour holes, etc. But because of the multi-step process and the expense of making a new silicone mode for each revision I never pursued it.
But I never considered milling the plaster directly. That would seem to be a better approach for the prototyping process. Then, if you wanted to make a lot of them, you could make a silicon mold of the perfected design and cast a bunch of them in plaster for metal casting.
Thanks for sharing this. I will have to give this a try sometime!
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