Lapmaster International - US

   501 W. Algonquin Rd.
   Mount Prospect, Illinois 60056

   Toll Free 877-FLATNESS

   Phone 224.659.7101
   Fax 224.659.7103

 

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Case Studies

Fine Grinding Applications

Case History No.1

Application: Water taps
Presented condition: As received from firing process.
Material: Ceramic.
Outside Diameter: 31.6mm
Thickness: 8.2 mm
Components: Ceramic tap seal faces

Requirements

  • Stock removal required from each face: 0.1mm (0.2mm total)
  • Thickness: 8mm+/- 0.010
  • Parallelism: 0.002mm
  • Flatness: 0.0006mm
  • Surface finish: 0.2/0.3 microns Ra
  • Production rate: 2400 per hour

Results

  • Thickness: 8 mm+/- 0.003
  • Parallelism: 0.002mm
  • Flatness: 0.0001mm
  • Surface Finish: 0.2 microns Ra
  • Production rate: 3075 per hour
  • Fine grinding time: 3 minutes

Process Data

  • Work carrier capacity: 41
  • Machine capacity: 205 per load
  • Process time: 3 minutes
  • Floor tofloor time: 4 minutes
  • Hourly production capacity: 3075
  • 8 hour shift capacity: 24600

Plate specification

  • Estimated plate wear: 0.18mm per shift
  • Carriermaterial: Mild steel
  • 70 micron bonded diamond

Case History No.2

Application: Ultrasonic Cleaners
Presented condition: As received from firing process.
Material: Barium Titanate
Outside Diameter: 37.7mm
Thickness: 6.5 mm
Components: Electrodes

Requirements

  • Stock removal required from each face: 0.75mm (1.5mm total)
  • Thickness: 5mm +/- 0.010
  • Parallelism: 0.0025mm
  • Flatness: 0.0025mm
  • Surface finish: 0.5 microns Ra
  • Production rate: 1000 per hour

Results

  • Thickness: 5 mm+/- 0.003
  • Parallelism: 0.002mm
  • Flatness: 0.0001mm
  • Surface Finish: 0.2 microns Ra
  • Production rate: 3075 per hour
  • Fine grinding time: 3 minutes

Process Data

  • Work carrier capacity: 24
  • Machine capacity: 120 per load
  • Process time: 3 minutes
  • Floor tofloor time: 4 minutes
  • Hourly production capacity: 1800
  • 8 hour shift capacity: 14400

Plate specification

  • Estimated plate wear: 0.18mm per shift
  • Carriermaterial: Mild steel
  • 70 micron bonded diamond

Inside Diameter: 15.8mm

Case History No.3

Application: Automitive Transmission.
Presented condition: Stamping.
Material: Hardened Steel.
Outside Diameter: 381.7mm
Thickness: 2.56 mm
Components: Shim - pinion head bearing

Requirements

  • Stock removal required from each face: 0.21mm (0.42mm total)
  • Thickness: 2.135mm +/- 0.010
  • Parallelism: 0.005mm
  • Flatness: 0.005mm
  • Surface finish: 0.4 microns Ra
  • Production rate: 650 per hour

Results

  • Thickness: 2.135 mm +/- 0.002
  • Parallelism: 0.002mm
  • Flatness: 0.0001mm
  • Surface Finish: 0.2 microns Ra
  • Production rate: 720 per hour
  • Fine grinding time: 2 minutes

Process Data

  • Work carrier capacity: 6
  • Machine capacity: 30 per load
  • Process time: 2 minutes
  • Floor tofloor time: 2.5 minutes
  • Hourly production capacity: 720
  • 8 hour shift capacity: 5760

Plate specification

  • Estimated plate wear: 0.18mm per shift
  • Carriermaterial: Mild steel
  • 70 micron bonded diamond

Inside Diameter: 64.3mm

Case History No.4

Application: Food Industry
Presented condition: Cold Rolled
Material: Stainless Steel 420, Hardness; Rockwell 88-95
Outside Diameter: 4.00"
Thickness: 0.062"
Components: Slitter Knives

Requirements

  • Stock removal required from each face: 0.002" (0.004" total)
  • Thickness: 0.058"+/- 0.0001"
  • Parallelism: 0.0002"
  • Flatness: 0.0002"
  • Surface finish: N/A
  • Production rate:
  • Surface finish: N/A
  • Production rate: 150 per hour

Results

  • Thickness: 0.0579/0.0581"
  • Parallelism: 0.0002"
  • Flatness: 0.0001mm
  • Surface Finish: 16-32 micro inch
  • Production rate: 500 per hour
  • Fine grinding time: 9 minutes

Process Data

  • Work carrier capacity: 6
  • Machine capacity: 30 per load
  • Process time: 9 minutes
  • Floor tofloor time: 10 minutes
  • Hourly production capacity: 180
  • 8 hour shift capacity: 1440

Plate specification

  • Estimated plate wear: 0.18mm per shift
  • Carriermaterial: Mild steel

Case History No.5

Application: Manufacturing
Presented condition: Ground
Material: Mild Steel
Outside Diameter: 1.171"
Thickness: 0.260"
Components: Spacers

Requirements

  • Stock removal required from each face: 0.006" (0.012" total)
  • Thickness: 0.249"+/- 0.0005"
  • Parallelism: 0.0003"
  • Flatness: Flat to concave
  • Surface finish: 10-16 micro inch
  • Production rate: 2,000 per hour

Results

  • Thickness: 0.2485/0.2495"
  • Parallelism: 0.00005"
  • Flatness: Flat to concave
  • Surface Finish: 16 micro inch

Process Data

  • Work carrier capacity: 41
  • Machine capacity: 246 per load
  • Process time: 2.3 minutes
  • Floor tofloor time: 5 minutes
  • Hourly production capacity: 2,957
  • 8 hour shift capacity: 23,616

Plate specification

  • Estimated plate wear: 0.10mm per shift
  • Carriermaterial: Acrylic
  • 70 micron Vitrified CBN

Inside Diameter: 0.5"

Case History No.6

Application: Manufacturing
Presented condition: Ground
Material: Hardend Steel 60RC
Outside Diameter: 1.627"
Thickness: 0.749"
Components: Gears

Requirements

  • Stock removal required from each face: 0.0085" (0.017" total)
  • Thickness: 0.7315"/0.7325"
  • Parallelism: 0.0003"
  • Flatness: Flat to concave
  • Surface finish: 10-16 micro inch
  • Production rate: 2,000 per hour

Results

  • Thickness: 0.7320/0.7323"
  • Parallelism: 0.0003"
  • Flatness: Flat to concave
  • Surface Finish: 16 micro inch

Process Data

  • Work carrier capacity: 38
  • Machine capacity: 228 per load
  • Process time: 1.5 minutes
  • Floor tofloor time: 5 minutes
  • Hourly production capacity: 2,957
  • 8 hour shift capacity: 2,736

Plate specification

  • Estimated plate wear: 0.10mmper shift
  • Carriermaterial: Acrylic
  • 70 micron Vitrified CBN

Inside Diameter: 0.5"