DIATRON HIGH-END DIAMOND DRESSING TOOLS

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1 DIATRON HIGH-END DIAMOND DRESSING TOOLS

1 SERMA: THINK, DESIGN, CREATE Diamonds have inspired legendary enterprise as well as worldwide industries.

Could there be new radically superior major applications? The answer is synthetic diamond!

Recent decades has seen engineers produce tiny crystals from pure carbon under heat and pressure.

Purity, crystalline perfection, and high strength make CVD and MCD logs the perfect match for any grinding process carried out on CNC machines; more than ever where high production

2 1 SERMA: THINK, DESIGN, CREATE Diamonds have inspired legendary enterprise as well as worldwide industries. Its special proprieties have also spawned what can legitimately be called a wealth of niche applications. But should we expect more from the innovation brought to life so far? Could there be new radically superior major applications? The answer is synthetic diamond! Replicating the conditions that first forged diamonds deep into the Earth s mantle in a lab has been for ages a hidden scientists dream. Recent decades has seen engineers produce tiny crystals from pure carbon under heat and pressure. Modern alchemist has finally succeeded in growing thin film through the synthesis of high pressure high temperature (HPHT) or by means of chemical vapour deposition (CVD). Purity, crystalline perfection, and high strength make CVD and MCD logs the perfect match for any grinding process carried out on CNC machines; more than ever where high production output requires no downtime waste in resetting indexable tool and/or interruption for replacing it outright. SERMA: think, design, create... 1 CVD/MCD: synthetic diamond... 2 DIATRON: shape and size... 3 DIATRON: options... 4 DIATRON: a winning choice... 5 DIATRON: nomenclature... 6 DIATRON: troubleshooting... 7 DIATRON: how to s... 8 MONOSYNT & special edition... 9 SERMA: smart solutions SERMA: approved quality DRESSING: theory and practice DRESSING: side effects DRESSING: parameters... 14

3 2 CVD/MCD: SYNTHETIC DIAMOND For almost all measures of performance there is a long list of features which makes synthetic diamond a superior alternative to natural diamond dressing tools for conditioning a grinding wheel: Superior hardness within a close frame Thermal conductivity that stands comparison with copper Low thermal expansion rate Withstand aggressive environment, including extremes of Ph The reliability that synthetic diamond tools convey to the process is a key point for newly designed dressing tools to outlast those with natural stones. KNOOP HARDNESS (Kgf/mm 2 ) Al HSS Al 2 O HM CBN PCD NAT. DIAM CVD Besides the shortage of natural resources due to intensive exploitation, will make CVD and MCD starts out as more consistent products because their manufacturing process is tightly controlled and predictable. When properly configured, the dressing tool, thanks to the uniform rectangular shape through the entire length, is then able to routinely provide steady results, cycle after cycle. The peculiar shape of the CVD needles is very apt to be hold strongly anchored hence providing a stable basis for extended tool life time. THERMAL CONDUCTIVITY (W/mK) CVD COPPER TEMPERATURE ( C) Stick to our wealth of information about dressing parameters or simply rely on your valuable long term knowl-edge not to mess around repeated trial. We can even trim the outline of any tool to meet the grinding wheel OD radius to avoid break-in period. Success is well ahead of time and money with DIA- TRON. Give it a try! Ask us for your own free sample or test items covered by our fully refundable policy. What we re looking for is a honest feedback, hopefully a comprehensive one: constructive criticism it s the only way to better ourselves. THERMAL EXPANSION (10-6 /K) 4,0 3,5 3,0 2,5 2,0 1,5 1,0 0, TEMPERATURE ( C)

4 3 DIATRON: SHAPE AND SIZE DS α R DC α DM SINGLE CHISEL MULTI DP DT R DK PYRAMID TWIN KONE 6F 6B 6H FLIESE BLADE HYBRID

5 DIATRON: OPTIONS 4 R α β α FL FL FLUID FLUID AS AS ASYMMETRIC ASYMMETRIC IN IN TILTED TILTED CO CO CENTERED CENTERED HA HA HALT HALT ANGLE ANGLE RO RO HM HM CARBIDE CARBIDE AF AF SHARP SHARP RHOMBIC RHOMBIC AN AN α α β B A M2,5 Ø1,0

6 5 DIATRON: A WINNING CHOICE HM AF RO FL AS AN HA CO IN DS DC DK DP DT DM 6M 6F 6H Browsing through types and options, DIATRON tooling has so much to offer with its feature rich sections variety, a wide range of possible patterns, different sintering binders and many more extras. Basically it is so easy to design and assemble purposely meant specific dressers or universal hardware suitable for a wide range of different applications. Synthetic CVD and MCD logs are securely and safely arranged in a metal matrix, built up in a hard and sturdy solid body able to work out the most intricate form. Because alignment matters, we have the right answer within the reach. L S ,2x0,2 0,3x0,3 0,4x0,4 0,6x0,6 0,8x0,8 1,0x1,0 SQUARE SECTION 1,2x1,2 1,5x1,5 It has a remarkable wear resistant attitude and, at the same time, fast heat transfer amazing proprieties. The excellent efficiency of CVD and MCD stationary dressers are confirmed under the most severe stresses: they show impressive performances even against the highly challenging microcrystalline Seeded gel or Cubitron type abrasives. In a limited number of applications they can compete versus rotary roller dressers. They are easy-to-use, maintenance free, powerful tools whose low running costs are still unsurpassed. DIATRON tools are worth every penny. L S ,2x1,0 0,2x3,0 0,4x1,5 0,5x3,0 0,6x1,0 0,7x1,0 0,8x3,0 RECTANGULAR SECTION 1,5x3,0 We can help you make a connection between the multiple versions available at your disposal and the very specific task you need to accomplish. DIA- TRON is tailored to customer s specification, custom designed and cut-to-fit for a specific chore-and-chock-full of more options than a Swiss army knife. From one to thousands, from single specialized unit to large volumes, we can easily meet your specification regardless you are on the market for replacement of traditional tools or looking for hi-end state-of-the-art dressers. It s high time for technology to prevail.

7 6 DIATRON: NOMENCLATURE 6B ( ) 06 AF FL EXTRA TYPE DRAWING STICKS NO. DIMENSIONS *STICKS NO. *DIMENSIONS *=ONLY FOR DIATRON HYBRID ADDITIONAL OPTIONS EXTRA FEATURES Ø SHANK HEXAGON THICKNESS TOOL TYPE TOOL BODY HEIGHT WIDTH LENGHT STICK SPACING INTERSPACE SECTION

8 7 DIATRON: TROUBLESHOOTING 1000 stick section wheel diameter T 1,2x1,2 1,0x1,0 0,8x0,8 0,6x0,6 0,4x0,4 0,3x0,3 0,2x0, wheel thickness stick section ,5 1,2 1,0 DT - 6H wheel thickness DS - DC - DK 6B - 6F ,8 0,6 0,4 0,3 0,2 grit size

9 HOW TO S Ø<10 DS/CO DT/HM T>400 6F/AN a<15 DRESSING OF ID GRINDING WHEEL Ø<10MM DRESSING OF GRINDING WHEEL T>400 MM FOR SiC WHEEL DRESSING OF ANGLE APPROACH WHEELS a<15 A ,8 0,8 0,8 0, C 0,2 30 C-C ( 5 : 1 ) 4 6,1 A ( 5 : 1 ) 30 BETTER BY DESIGN 5 10 C 6F/AN 6M 6F/IN a<15 a>15 45 CNC DRESSING MULTI-TASKING DRESSING DRESSING OF ANGLE APPROACH WHEELS a>15

10 9 MONOSYNT MS 6M 6S SINGLE BLADE FLIESE Single crystal synthetic diamonds (MCD) are obtained through HPHT process and can deliver outstanding benefits too. They have the clear advantage of a higher hardness while on the other hand real drawbacks reside in a more expensive price along with a cleavage direction, a privileged plane where higher wear rate is observed. So MCD logs are bound to be deployed at their full supremacy in few cases when nocompromise high demanding applications require quality over low price target. SPECIAL EDITION 3D α 3F R 3H R ROUND CARVE ULTRA For several non-conventional application as well as for practitioner, lover of the very old-fashioned way, forward-thinking trend setter, we can manage extraordinary fitting of any available synthetic diamond sticks to be sintered inside the most bizarre body. There s no limit to your vision, CVD and MCD are likely to stand up to excruciatingly heavy duty operations. Is to be highlighted again as a stark reminder that the decline in natural stones usage is unstoppable. The only future is synthetic diamond.

10 SERMA: SMART SOLUTIONS Everyday tribulation can turn into Herculean efforts. Spend less time cruising around trial and error routine: just trust in our large portfolio of opportunities.

DIATRON tools sum up good diamond retention, multiple relaps, pullout prevention, and good flexibility to several tasks.

Craftsmanship is the master of excellence: it relies on fine workmanship, modern designs, distinct precision in detailing and finishing every single part.

11 10 SERMA: SMART SOLUTIONS Everyday tribulation can turn into Herculean efforts. Spend less time cruising around trial and error routine: just trust in our large portfolio of opportunities. So far we have overemphasized the importance of having a diamond dresser that cuts readily and subjects the wheel to less pressure. DIATRON tools sum up good diamond retention, multiple relaps, pullout prevention, and good flexibility to several tasks. It resembles the quintessential qualities a dressing tool has to cope with, thanks to its unique characteristics always in compliance with the highest standard. Craftsmanship is the master of excellence: it relies on fine workmanship, modern designs, distinct precision in detailing and finishing every single part. Our company went throughout more than 30 years of uninterrupted activity focused in grinding applications. With the kernel inside such deep roots, the company s knowledge is rock-solid. We take care of each dresser in minute detail but, to take every advantage of DIATRON, an inquiry which fully survey the existing process will help us troubleshoot any issue you may have encountered. We will advise our DIATRON proposal. A winning combination of applied techniques and inspiration is what has allowed us to pull ahead whenever a problem s got tough. SERMA has the customer s best interests at heart, and is strongly committed to its cause. Although to this end we ve strived to find out brilliant ideas, creative design, different al-ternatives nevertheless we do still want to maximize the ratio benefits/costs you re aiming at. We are prone to seek out new and better ways to improve your productivity: our profits have always been reinvested in new machinery to gain problem solving abilities.

11 SERMA: APPROVED QUALITY QUALITY INSURANCE An high-end and up-to-date inspection room is the cornerstone for our production: all the processes flow through it.

TRACEABILITY Every step in the process chain is well documented and then recorded to be kept in perpetuity.

objectives. INSPECTION SHEET Paperwork is another key component and, after having finished the part, work must be audited accurately. An inspection sheet is released to confirm feature or GD&T sizes.

12 11 SERMA: APPROVED QUALITY QUALITY INSURANCE An high-end and up-to-date inspection room is the cornerstone for our production: all the processes flow through it. We have devoted a lot of energy on lean methods of productivity to get the most out the shopfloor. Quality will sustain our company longer into the future. TRACEABILITY Every step in the process chain is well documented and then recorded to be kept in perpetuity. Lately we have switched off into a brand new ERP so that all our activities from business down to ISO9001 quality management are integrated and dynamically scheduled to help us achieve our stated objectives. INSPECTION SHEET Paperwork is another key component and, after having finished the part, work must be audited accurately. An inspection sheet is released to confirm feature or GD&T sizes. This makes the product the real and only centrepiece. STUDY & SIMULATION 3D CAD software can accommodate for more creative and experimental with designing new and sometimes exotic tools. It add values without any mark-up to end-users but a mere approval drawing subject to be reviewed for error-free final cross-checking. INVENTORY Another benefits is our inventory stocked of up to 100s items which account for last-minute request. Retailers are very welcome: we will fulfil any of your detailed desire or instructions.

One properly set pass is more than enough, and back travel to remove dangling grit is useless.

13 12 DRESSING: THEORY AND PRACTICE Fn Ft FORCES It s no secret that too heavy a pass seriously threaten the diamond structural integrity. Too light a stroke as much as a fairly aggressive pass should be avoided, or rather only conceived for what they re meant (i.e. pre-profiling/re-truing a used wheel or mirror finishing achievements with slow feed rate). One properly set pass is more than enough, and back travel to remove dangling grit is useless. During the dressing path the diamond is subject to a normal force which can peak as high as 150 N depending upon type, number of sticks, settings, etc. Such heavy pressure is responsible for the stresses and the input heat the dressing diamond is bound to suffer. DIA-TRON dressers do not become blunt yet their life span can stretch further on with basic thoughtful treatment. HEAT Heat develops because of friction at the contact point and is to be carefully avoided not to burn away prematurely the diamond tool. The true carbon-like nature of the diamond tend to have it converted into graphite (an allotropes of carbon) at temperature of approx. 800 C. An earlier stage, which is an unmistakable sign of over-heating, is the oxidation of the external surfaces which turn into a deep black nuance. Though not yet phase transitioned, this is a preliminary step before irreversible change may occur. Do always prevent diamond dressers from thermal shock: exposing CVD needles to extreme temperature gradient can result in cracking or breaking. This causes the whole atomic structure to fail dramatically. Supply a generous flows of fluid to cool down diamond. VIBRATIONS It is a truth universally acknowledged by practitioners, skilled machinists and well educated engineers, that vibrations are harmful to whatever machine shop practice. Dressing tools are no exception. Despite inner issues due to poor finishing or clamping (i.e. sintering into the metal matrix, or weak weld brazing the shank, and even loose fit in the holding device) the utmost care should be taken to outer sources of disturbance. It s well worth the extra effort to check out for wheel unbalance, for flimsy support, for ball screws allowance, or even for worn out slides that weakens the machine integrity. All in all they affect the dressing process more than you could ever think of. Too often dressing tools are blamed for faulty process while others deserve better control to fix issues beyond common understanding.

13 DRESSING: SIDE EFFECTS UNDERCUT In angle-approach plunge grinding the difference of diameters across the wheel width poses serious concern due to surface speed delta especially while dressing with

This eventually turns out into a tapered wheel since a considerable amount of the wheel is cut away by the outer overexposed corners of the tool.

A faithful duplicate as close as possible to the original pattern can be ground only if proper geometry is lapped and certified DIATRON tools has the virtue to be carved out at an exactly shape and

14 13 DRESSING: SIDE EFFECTS UNDERCUT In angle-approach plunge grinding the difference of diameters across the wheel width poses serious concern due to surface speed delta especially while dressing with blade or fliese types dressers. When the tool is fed in, the smaller OD is copied into the tool itself which then, along its path, travels towards the bigger OD creating interference. This eventually turns out into a tapered wheel since a considerable amount of the wheel is cut away by the outer overexposed corners of the tool. In such cases extra attentive brainstorming has to be carried out for a proper form Dressing stepped profiles by means of a template or by CNC can be tricky either. A faithful duplicate as close as possible to the original pattern can be ground only if proper geometry is lapped and certified DIATRON tools has the virtue to be carved out at an exactly shape and is best for profile capability requirement under strict tolerance. Whether it is concave or convex radii DIATRON logs are held so intimately they are safe and sane even if the metal bond is damaged. No unexpected offset neither jamming through mind boggling trial-and-error any longer. Grinding is undoubtedly a machining method which can still produce workpieces of the highest accuracy: getting comparable GD&T standards is still a challenging task for any high-tech machine tools. It is of paramount importance a fine tuned set-up of the dressing cycle. We do strongly recommend the diamond dresser is tightly screwed in to its holder and this latter is set to the centreline near to the grinding zone. A piece of advice much disregarded account for conicity issue whose reason lies in the misalignment of the wheelhead (no matter tis only tenth of microns!).

14 DRESSING: PROCESS PARAMETERS Dressing it is essential to prepare the grinding wheel in order to make it ideal for Truing to deviation-free rotating form Cleaning up to remove a loaded layer of

15 14 DRESSING: PROCESS PARAMETERS Dressing it is essential to prepare the grinding wheel in order to make it ideal for Truing to deviation-free rotating form Cleaning up to remove a loaded layer of worn abrasive Sharpening to have an even allocation of cutting points Truing is vital to have the wheel concentric with the center of the spindle. Cutting away a glazed or loaded grinding surface is fundamental to get sharp, jagged points that can remove chips out of a piece quickly. A properly dressed wheel is a major step towards accuracy and good finish. It is straightforward to figure out how the diamond dressers build up a helix in its motion moving across the dressing path. The depth of cut and the dressing feed per revolution of the grinding wheel create a helical groove on the wheel surface whose final topography result in a large density of freshly, brand new, and well exposed cutting edges randomly distributed over the entire wheel width. The texture it influences the overall grinding performance. DIATRON let you take full control over your dressing process for stunning achievements FEED (mm/min) RPM GRIT SIZE In pursuing the right blend between theory and practice, a fair compromise should be found by machinist and engineers as well. Finishing and cutting ability are often times a crucial test. In this regard it is paramount, to realize grinding s full metalworking potential, to interactively work in conjunction with our technical department. Practice cannot be mastered easily, nor it can be controlled by simple formulas and recipes: anyhow stick to our guide-lines which put together rules and know-how. Ra 6,3 N ,15 N8 1,6 N ,8 N ,4 N ,2 N ,1 N ,05 N ,025 N ,16 0,25 0,4 0,63 1,0 1,6 2,5 4,0 6, Rt

A14 Latitude N44.52845 Milano Via Marco Emilio Lepido Longitude E11.

Via Dell Aeroporto 4 Via del Triumvirato 4bis Ancona Design & contents: Roberto Giovannini DINR - rev.

16 A14 Latitude N Milano Via Marco Emilio Lepido Longitude E Via Persicetana Via Persicetana Vecchia Via Della Salute Via Due Portoni A14 Via Bencivenni Firenze Via Dell Aeroporto 4 Via del Triumvirato 4bis Ancona Design & contents: Roberto Giovannini DINR - rev. 1-09/15 SERMA S.r.l. Via Due Portoni, Bologna (IT) Tel. +39-(0) Fax. +39-(0) info@sermasrl.it - web:

FINE GRINDING TECHNIQUE & TECHNOLOGY Ø 810

FINE GRINDING TECHNIQUE & TECHNOLOGY 7 3 Ø 80 e Grinding: a cost efficient process e Grinding: D & CBN superabrasives e grinding, also known as flat honing, refers to a type of high accuracy grinding operation