ELECTROPLATED DIAMOND TOOLS
UKAM Industrial Superhard Tools manufactures Precision Electroplated Diamond Products from 0.5 microns to 20 grit (diamond mesh size) in Synthetic, Natural Diamond or CBN (cubic boron nitride). For a large variety of applications, materials, and industries. Electroplated Diamond Products Manufactured by UKAM Industrial are Multi Layered. They have 3 layers of diamonds, not just 1 layer of diamonds like conventional electroplated diamond tools.
UKAM Industrial Superhard Tools has over 50 years of experience in manufacturing, research, and development. We are at the forefront of technology and are constantly engaged in Research & Development. Following the belief: "There is always room for improvement" We continue to raise standards for the whole industry. Our products are used in High Production, Research & Development, and Hobby applications. Customers include some of the leading Fortune 500 companies, Military, Science & Space Organizations, Small Machine Shops, Contractors & Hobby Enthusiasts. We also pride ourselves in manufacturing tools that are used in our nations mission critical applications, involving defense and national security. As well as exciting & breakthrough fields such as: MEMS & Nano Technology.
Examples of Multi-Layered Electroplated Diamond Products manufactured by UKAM Industrial Superhard Tools
UKAM Industrial Superhard Tools has over 50 years of experience in manufacturing a large variety of products for industry, Research & Development, as well as hobby. Only the highest quality synthetic or natural diamonds and raw materials are used in the manufacturing process. The highest quality standards and product consistency is maintained, using sophisticated inspection and measurement equipment. Standard (off the shelve) electroplated diamond products include: diamond drills, diamond micro drills, ultra thin diamond blades, diamond burs, diamond grinding wheels, and much more.
In addition to manufacturing standard electroplated diamond products, UKAM Industrial Superhard Tools can electroplate diamonds on just about any material or substrate per customer drawing and specifications. Our stripping System allows a tool blank to be Stripped & Replated as many as 100 times over before loosing .0000001" of the surface. We pride ourselves in working with some of the leading glass, composite, semiconductor, stone, and optics manufacturers.
UKAM Industrial Superhard Tools can design and manufacture just about any diamond product to better fit you needs, specifications, standards, and requests. Our Experienced Engineers and Application laboratory, equipped with some of the latest Slicing, Dicing, Wafering, Drilling, & Micro Drilling Equipment is available to help you develop not only the right tools, but the Right Process for your specific Material/Application. We will work with you to determine your needs, and recommend the right solution for your specific material/application. Let us help you improve your Diamond Machining operation to its ultimate level of efficiency.
SELECTING THE RIGHT DIAMOND TOOL FOR YOUR APPLICATION
Typical Electroplated Diamond Tool Applications / Materials Used On:
|Alumina||Glass Bonded Mica||Silicone||Onyx|
|Beryllium Oxide||Barium Titanate||Transmission Bands||Clutch Linings|
|Brake Linings||Epoxy||Taped Graphite||Glass Laminated|
|Cerments||Optical Materials||Composites||AND MANY OTHERS|
Electroplated Diamond Tools are Frequently used in following Industries:
|Missle||Casket||Paneling||Tank (Water & Acid)|
|Diving Board||Pool Slide||Swimming Pool||Form Grinding|
|Marble||Glass||Composites||AND MANY OTHERS|
Diamond - mainly used on any nonferrous materials, such as: carbides, ceramics, glass, fiberglass, reinforced plastics etc., and CBN is for use on ferrous materials, tool and diesteels, high alloy steels and nickel rich alloys.
CBN (cubic boron nitride) - mainly used on tool and die steels, high alloy steels, and nickel rich alloys.
To obtain optimum diamond machining results, from our electroplated diamond tools. We recommend following general grinding guideline with both Diamond and CBN tools:
|Diamond Definition||Diamond Mesh Size||
Thickness of Diamond Coating
Size of each particle A
Size of each particle B
|Roughing (Heavy Stock Removal)||0.010"||0.0015"|
|Medium Roughing (General Grinding)||0.008"||0.0013"|
|Semi Roughing (Semifinish Grinding)||0.0075"||0.0012"|
|Rough Finishing (Finish Grinding)||0.005"||0.001"|
|Extra Fine||270/325||0.0064"||Fine finishing||0.0025"||0.0007"|
|Super Fine||325/400||0.005"||Extra finishing||0.002"||0.0005"|
|45 Microns*||400/500||0.0034"||Super finishing||0.0015"||0.0002"|
|9 Microns* 8/10 6/12||1,800||0.0007"||Polishing||0.00035"||0.00008"|
|6 Microns* 4/8||3,000||0.00048"||Fine polishing||0.00024"||0.00008"|
|3 Microns*||8,000||0.00032"||Extra polishing||0.00016"||0.0000075"|
* Not recommended for removing more than .000001" per pass.
SURFACE FINISH REQUIREMENTSDue to the aggressive nature of diamond and CBN electroplated products, "super fine" finishes can be difficult to achieve. The following will help you select the appropriate grit size to achieve your required finish:
|GRIT SIZE||APPROXIMATE RMS|
|45 Micron (400)||13-14|
|30 Micron (600)||12|
|15 Micron (1200)||12|
*When converting from conventional aluminum oxide or silicon carbide wheels to electroplated products, double the conventional grit size to find the equivalent electroplated grit size. For example: a 60 grit Aluminum Oxide would equal 120 grit electroplated.
|DIAMOND PARTICLE SIZE CHART|
Total tool tolerance for electroplated diamond tools is determined by sum of backing material tolerance and respective profile tolerance. Specific tolerances are available on many tools upon request.
ELECTROPLATED DIAMOND TOOLS SHAPE & ACCURACY
Electroplated diamond products are an excellent choice for applications requiring repeating specific shapes or close tolerances or both. Its important for the End User / Customer to be familiar with the specific tolerances and sizes of the abrasive particles to insure the manufacturing feasibility of the electroplated diamond wheel or tool.
FOR MACHINING BLANKS WITH RADIUS
For example, the female radius in the steel blank must be larger than the finished diamond plated size and so naturally a male radius must be smaller. Just how much larger or smaller the radius must be depends on the diamond grit (mesh) size selected. Based on the required grit size and the specifications on the form we can determine the manufacturing feasibility of your electroplated diamond tool.
Female radius on the steel blank must be larger than the finished size required
Example: If a 0.250" female radius is needed with 100/120 Grit.- How much larger than the finished radius should the tool radius be? 100/120=0.0075", therefore 0.250" + 0.0075=0.2575
Male radius on the steel blank must be smaller than the finished size required
Example: If a 0.250" male radius is needed with 100/120 Grit.- How much smaller than the finished radius should the tool radius be? 100/120=0.0075", therefore 0.250" - 0.0075=0.2425
RECOMMENDED STEEL BLANK MATERIALS
Blank material hardness should be about 50 to 60 on Rockwell scale of hardness. Diamonds usually provide best adhesion to materials with high carbon content. High speed steels such as 4130, 4140 usually used for most blanks to be electroplated with diamonds. Steel used should have no lead content.
TYPICAL SPEEDS & FEEDS for ELECTROPLATED DIAMOND TOOLS
you have determined the appropriate diamond mesh (grit size) for your
application, it's important to know if you have the speeds necessary to have
your diamond tools operate to its ultimate potential. This is particularly
important with CBN which requires high speeds and pressure to perform
Feed rates are dependent on workpiece material ranging from fine furnishing cuts
to high energy deep grinding. Ask your UKAM Industrial Superhard Tools engineer / representative for recommendations on your specific application
Diamond: 5,000 to 6,000 SFPM (Surface Feet Per Minute)
CBN: 6,500 to 12,000 SFPM
SFPM = Wheel Speed in RPM's X Wheel Diameter in Inches X .262
COOLANTS & ELECTROPLATED DIAMOND TOOLS
(Synthetic or Natural)
Electroplated diamond tools can be used dry, however, the life & performance of the tool will be significantly superior when used with coolant. Frequent coolants used with diamond electroplated tools include plain water or Synthetic Water Soluble Coolants, such as SMART CUT coolant. Synthetic water soluble coolants are recommended and will promote superior tools performance, life, and consistency.
(Cubic Boron Nitride / Borazon)
Straight oil coolants are frequently used with CBN (cubic boron nitride) diamond tools. Recently due to rising health and environmental issues associated with straight oil coolants, most companies are are using new synthetic water soluble oil coolants, such as SMART CUT coolant. Many companies today are achieving success with these water based oil coolants when working with CBN tools. Please remember that life of electroplated diamond tools will be lower with used dry or with water based coolants.
What you should know before you buy your next diamond tool?
UKAM Industrial Superhard Tools Division of LEL Diamond Tools International, Inc.
28231 Avenue Crocker, Unit 80 Valencia, CA 91355 Phone: (661) 257-2288 Fax: (661) 257-3833