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2011 almt catalog

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ALMT Diamond Products

ALMT Diamond Products


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  • 1. Precision Diamond Tooling Catalog A Sumitomo Company
  • 2. Introducing...basic and advanc INDEX P 1 - 2 …… INDEX P 3 - 4 …… Wheel/General P 5 - 6 …… Bond Types P 7 - 8 …… Wheel Shape 1 P 9 - 10 …… Wheel Shape 2 P11 - 12 …… Wheel Shape & Trueing Grinding Tools Grinding Tools Grinding Tools Grinding Tools P13 - 14 …… Resiace P13,14 P15,16 P17,18 RESIACE Flute Max CBM Bond Wheel P15 - 16 …… Flute Max P17 - 18 …… CBM Bond Wheel P19 - 20 …… Hybrid Wheel P21 - 22 …… MT Bond Wheel P23 - 24 …… CP Wheel P25 - 26 …… Vitrified Bond Wheel P27 - 28 …… Vitrified Bond Wheel Grinding Tools Grinding Tools Grinding Tools P29 - 30 …… MB Spark P28 P29,30 P31,32 Easy Wheel MB Spark DPG Wheel P31 - 32 …… DPG Wheel P33 - 34 …… Nanomate & CMP Conditioner P35 - 36 …… Types P37 - 38 …… Production Range Dresser P39 - 40 …… Dimensional Accuracy P41 - 42 …… Options P43 - 44 …… Inspection Dresser Dresser P36~ P41,42 P45 - 46 …… Technical Information Rotary Dresser Rotary Dresser Option P47 - 48 …… Dresser/Other P49 - 50 ……Types P51 - 52 …… Features of Ultra Precision Cutting Tools P53 - 54 …… UPC Nano-microforming Cutting Tools (-R, -F, -T) P55 - 56 …… UPC P57 - 58 …… New D P59 - 60 …… e-EDGE Cutting Tools Cutting Tools Cutting Tools P53 P54 P54 P61 - 62 …… Features of PCD Cutting Tools UPC Nano Groove UPC Nano Endmill UPC Nano Profile P63 - 64 …… Processing Ex. of PCD Reamer & Endmill P65 - 66 …… Prod. Range of PCD Reamer & Endmill P67 - 68 …… PCD Circular Saw P69 - 70 …… PWS Other P71 - 72 …… Machinery & Coolant P73 - 74 …… Miscellaneous Products P75 - 76 …… CTC Cutting Tools Cutting Tools Cutting Tools P61,62 P65 P66 P77 - 78 ……Network PCD Reamer PCD Reamer PCD Endmill1
  • 3. ced diamond & cBN tooling from A.L.M.T. A.L.M.T. Corp. offers a wide range of products to meet all of your cutting, grinding, and polishing needs. Thank you for using A.L.M.T. Grinding Tools Grinding Tools Grinding Tools Grinding Tools Grinding Tools Grinding Tools P19,20 P21,22 P23,24 P25 P26 P27 Hybrid Wheel MT Bond Wheel CP Wheel Vitrified Bond Wheel Vitrified Bond Wheel Vitrified Bond Wheel Grinding Tools Grinding Tools Grinding Tools Grinding Tools P33 P33 P34 P34 Nanomate Nanomate CMP Conditioner CMP Conditioner Dressers Dressers Dressers Dressers Dressers P47 P47 P48 P48 P48 One Circle (Straight) One Circle (Cup) Crown Dresser CVD Ace Dresser Disc Dresser 切削ツール Cutting Tools Cutting Tools Cutting Tools Cutting Tools CuttingP55 Tools P55 P56 P56 P57,58 P59,60UPC-R UPC-R UPC-F UPC-T New D e-EDGE Cutting Tools Misc. Items Misc. Items Misc. Items Misc. Items Misc. Items Misc. Items P67,68 P69,70 P69,70 P71 P72 P72 P73 Internal Grinding Pin PCD Circular Saw PWS-R PWS-E CPG Tool Grinder Brake Dresser ODIUP (Coolant) P74 Diamond File 2
  • 4. Diamond ToolsWheel Figure Precise Diamond & cBN Grinding Tools Type of Bond Resin B Metal M Vitrified V Electro-plated E Abrasive Type JIS Display Natural Diamond D Synthetic Diamond SD Coated Synthetic Diamond SDC Cubic Boron Nitride cBN* Coated Cubic Boron Nitride cBNC* Identification System of Diamond & cBN Wheel Abrasive Type Bond Strength Bond Type Bond Thickness SDC 200 N 100 B S40 3.0 Mesh Size Abrasive Concentration Bond Name 3
  • 5. Diamond Abrasive Natural Diamond Resin Bond Metal Bond Coated Resin Bond Mesh Size cBN Abrasive Display Average JIS Size ( m) 16 16/20 1190 20 20/30 840 30 30/40 590 Monocrystal Polycrystal Coated Monocrystal 40 40/50 420 50 50/60 300 Concentration 60 60/80 250 Degree of Grain Content ct/cm(mg/cm3) 3 80 80/100 177 Concentration 100 100/120 149 150 6.6 (1320) 120 120/140 125 125 5.5 (1100) 140 140/170 105 100 4.4 (880) 170 170/200 88 75 3.3 (660) 200 200/230 74 2.2 (440) 50 230 230/270 63 Notes: 1ct=200mg 270 270/325 50 325 325/400 44 Bond Strength “N” is standard and indicates the bonding of the abrasive and bond. 400 37 600 30 800 20 1000 15 Soft Hard 1500 10 N 2000 8 J     L P     R 3000 5 Material Processed by Diamond or cBN Wheel DiamondCutting Tool Electric Parts Magnetic Material Crystalline Material Ceramic Products Wear Resistant Metal Plastic GraphiteTungsten carbide Ceramic Ferrite Glass Stone Sprayed Metal F.R.P. General WheelCermet (Aluminum Rare earth Crystal Refractory Material Stellite JewelryCeramics nitride, etc.) Quartz Tile(Alumina, etc.) Silicon Compound Sapphire Asphalt semiconductor Concrete cBN Wear Resistant Structural Corrosion Resistant Heat Resistant Magnetic Material Cutting Tool Tool Component Metal Metal Cast Iron SKH SKD SCM SUS SUH Sendust SKS Sprayed Metal SNCM Inconel Alnico SK Stellite SCr Ti Alloy SUJ Nimonic 4
  • 6. Diamond ToolsWheel Figure Resin Bond Wheel These consist of bonding-added resin in main proportions to various fillers. Phenol resin is mainly used but polyimide resin, which has better heat resistance, is becoming more common. FluteMAX can provide great grinding results for creep feed grinding in any kind of material. Characteristics 1 Small new modules and good surface roughness Maintains good grinding ability during the 2 cutting of resistant material Characteristics 1 Small new modules and good surface roughness Grinding wheel FluteMAX Maintains good grinding ability during the 2 cutting of resistant material Usage Metal material such as tungsten carbide, cermet, and high speed steel Usage From rough to finish grinding for certain materials such as fine ceramics, ferrite, and Cutting wheel Metal material such as tungsten carbide, glass cermet, and high speed steel From rough to finish grinding for certain materials such as fine ceramics, ferrite, and Metal Bond Wheel glass Metal Bond Wheel consists of various types of alloys: copper, tin, silver, steel, Characteristics cobalt, and tungsten. MT Bond Wheel has excellent grinding ability as well as long tool life and is highly recommended for ceramics, carbide, and cermet. strong gripping 1 High wear resistance and of abrasive 2 Good grinding ability on glass and ferrite Characteristics 1 High wear resistance and strong gripping of abrasive 2 Good grinding ability on glass and ferrite MT Bond Wheel CP Wheel Usage Rough grinding for certain materials such as glass, ceramics, ferrite, semiconductor material, and stone Usage Profiling of tungsten carbide Rough grinding for certain materials such as glass, ceramics, ferrite, semiconductor DPG Wheel Core Drill material, and stone Profiling of tungsten carbide 5
  • 7. Vitrified Bond WheelCeramic bond-added glass is the main component to theVitrified Bond Wheel. VITMATE has a specially developedbond for cBN and Easy Wheel. Main material applicationsare carbide and ceramics, but is capable of grinding othermaterials as well. Characteristics 1 High trueing and dressing ability due to high hardness as well as accuracy of air hole 2 Trueing and dressing can be acheived easily using VITMATE with a Rotary Dresser on the machine VITMATE HIG-V 3 HIG-V uses a special bonding technique for high speed usage Usage Steel, tungsten carbide, and ceramics, etc. Suitable for high efficiency processes of high speed grinding CPV Easy WheelElectroplated WheelBonding plated occurs on just a single layer of metal corewith Ni plating. Pyramid wheel was designed to improveevacuation of grinding chip, especially in soft material, andleads to increased grinding ability. Characteristics Characteristics 1 Maintains exceptional grinding ability due 1 Maintains exceptional grinding ability due to high protrusion to high protrusion 2 Stable processing accuracy due to high 2 Stable processing accuracy due to high density and high wear resistance density and high wear resistance 3 Easy to form and reusable body 3 Easy to form and reusable body Gear Grinding Super Sizing 4 Excellent chip evacuation 4 Excellent chip evacuation Usage Usage Diamond Diamond Rough grinding or forming of carbide and Rough grinding or forming of carbide and ceramics, etc. ceramics, etc. Soft material such as rubber or FRP Pyramid Wheel Chamfering Wheel Soft material such as rubber or FRP cBN cBN Forming of steel, inner grinding and gear Forming of steel, inner grinding and gear grinding, etc. grinding, etc. 6
  • 8. Diamond Tools Identification Method of Wheel ShapeWheel Figure 1 2 3 4 6 A 2 C 1 Standard Body Shape 2 Cross Sectional Shape of Abrasive Layer 1 8 A D FF L QQ 2 11 AH DD G LL S 45°-90° 3 12 B E H M U <45° 4 14 C EE J P V 6 15 CH F K Q Y 3 Abrasive Layer Position & Symbol Reference to Body 4 Modification & Symbol Symbol Position Diagram Symbol Modification Diagram B Spot Facing Hole 1 Outer Boundary Countersinking C Hole H Straight Hole Straight & 2 Side M Threading Hole P Relief at One Side 3 Both Sides Insert of Q Abrasive Layer Incline or 4 Roundness, Inside R Relief at Both Sides Incline or 5 Roundness, Outside Segmented S Abrasive Layer Part of 6 Outer Boundary 7 Part of Side Slot Segmented SS Abrasive Layer 8 Whole Edge T Threading Hole 9 Reverse Inner V Attachment 10 Circumference of Abrasive Layer W With Shaft Reverse Insert Y of Abrasive Layer 7
  • 9. Standard Wheel Shape1 1A1 Straight D X T H3A1/14A1 Straight with Boss D X T U H1F1/1FF1 Straight with R D X T R R H1EE1/1E6Q V Face D X T V H V T H1Q1/1L1 Chipbreaker D X R T H R1DD6Y Centering D1 D X 45° 20 U H 45° 8
  • 10. Diamond ToolsWheel Figure Standard Wheel Shape 2 Standard Wheel Shape 2 1A1R Cutting 1A1R Cutting D D X X T T H H 1A1RSS Cutting Saw 1A1RSS Cutting Saw D D X X T T H H 1V1 Straight with Angle 1V1 Straight with Angle D D X X T T H V H V 4B2 One Side V Face 4B2 One Side V Face D D W V W V T T X H X H 9U1 U-shaped Straight 9U1 U-shaped Straight D D W X X W X X T T H H 1FF6Y/1EE6Y/1LL6Y/1DD6Y Pencil Edge 1FF6Y/1EE6Y/1LL6Y/1DD6Y Pencil Edge D1 D D1 D X X U V T U V T H H 9
  • 11. Standard Wheel Shape 3 Standard Wheel Shape 3 6A2 6A2 Plain Cup Plain Cup DD WW X X T T HH11A2/11B2 11A2/11B2 Flair Cup Flair Cup DD X X WW T T HH 6A9/11V9 6A9/11V9 Corner Cup Corner Cup DD X X WW T T HH11V2S 11V2S Wedge-shaped Segment Cup Wedge-shaped Segment Cup DD W 45° 45° W X T X T HH 3A2 3A2 Core Drill Core Drill LL BB W XX W D S D S 3F2 3F2 Curve Generator Curve Generator XX W XX W W XX W W W D D D D D D XX XX W W W W D D D D 10
  • 12. Diamond ToolsWheel Figure Standard Wheel Shape 4 Standard Wheel Shape 4 6A2S Segment Cup 6A2S Segment Cup D D W X X W T T H H 11C9/11Y9 L-shaped Flair Cup 11C9/11Y9 L-shaped Flair Cup D D W X W X T X T X H H 12A2 Dish 12A2 Dish D D W X W X T T H H 9A3 Both Side Cup 9A3 Both Side Cup D D W X W X T T H H 3V2T Chamfering 3V2T Chamfering L X L Set with Core Drill (3A2) X Set with Core Drill (3A2) W W D D 45 ゜ 45 ゜ W Internal with Shank W Internal with Shank L T L T X X Y D Y D11
  • 13. About Trueing and Dressing Dia. 1. Method of Trueing for Each Type of Diamond and cBN Wheel Trueing Method and Tool Applicable Applicable Bond Abrasive (*1 *2) Forming Remarks Dia Easy Wheel Possible Rotary Dresser cBN V.B Possible Rotating Dia Easy Wheel Possible Type Metal Wheel Used mostly with cBN cBN V.B.M.(E) Possible wheel; cannot be applied Electrodeposition Arbor cBN V.B Not Possible to diamond except in Diamond Tool Single Point, Multi-point Dresser cBN V.B Not Possible some cases Method Impregnated Dresser cBN V.B.(E) Not Possible Static Type Block Dresser cBN V.B Possible Electrodeposition Block Dresser cBN V.B.(M) Not Possible Rotating Dia B.V.M Possible Rotating Type can be Grinding Wheel Conventional Type cBN B.V.M Possible used for most diamond Wheel and cBN but Static Type Static Dia B.V.(M) Not Possible Method Stick is very limited Type cBN B.V.(M) Not Possible Rotating Dia B Not Possible Soft Steel Roll Type cBN B Not Possible Simple way applied from Soft Steel Method long ago; forming is not Static Dia B Not Possible possible Soft Steel Block Type cBN B Not Possible Free Abrasive Dia B.V.M Not Possible Lapping Method cBN B.V.M Not Possible Dia V Possible Crash Method Steel Roll Specialized equipment cBN V Possible is required Electro-discharge Dia M Possible Electrode Machining cBN M Possible *1: B: Resin Bond M: Metal Bond V: Vitrified Bond E: Electro-plated Wheel *2: Order of easiness for trueing; () is not generalFig. 1. Illustration of Trueing and Dressing Bond BondAbrasive Abrasive Dia. 2. Method of Dressing for Each Type of Diamond and cBN Wheel Dressing Method and Tool Applicable Abrasive Applicable Bond Trueing Dressing Dia Easy Wheel Rotary Dresser cBN V Rotating Type Dia Easy Wheel Metal Wheel cBN V Diamond Tool Method Single Point, Multi-point Dresser cBN V Static Impregnated Dresser cBN V Type Block Dresser cBN V Rotating Dia B.V.M.E Grinding Type cBN B.V.M.E Conventional Wheel Method Static Dia B.V.M.E Stick Type cBN B.V.M.E Rotating Dia B Soft Steel Roll Type cBN B Soft Steel Method Static Dia B Soft Steel Block Type cBN B Free Abrasive Lapping Dia, cBN B.V.M.E Method Blasting Dia, cBN B.V.M Crash Method Steel Roll Dia, cBN V Electro-discharge Machining Dia, cBN M Electro-chemical Machining Dia, cBN M *1: B: Resin Bond M: Metal Bond V: Vitrified Bond E: Electro-plated Wheel Order of easiness for dressing 12
  • 14. Grinding Resin Bond Wheel Diamond/cBN Lapping Plate RESIACE MB Spark was developed to meet the needs of surface quality improvement of elements used in automotive and household appliance in the progress of energy saving and miniaturization. MB Spark changes the world of double disc grinding by improving the trueing interval over a conventional resin bond grinding wheel, in combination with electro-discharge trueing. Heavy Duty Ultimate superheat Grinding resin bond RESIACE exhibits high performance in heavy duty grinding, particularly in cemented carbide or cermet applications. It performs especially well in heat resistant grinding processes without experiencing deformation. Heat Resistance Comparison Special Features 0 High Heat Resistance   Bond does not experience heat deteriorization even under severe -10 grinding conditions Rate of Weight Change (%) Superior Grinding   Highly efficient grinding due to superior ability and exceptional -20 durability -30 High Shape Retension   No need for shape correction -40 -50 Usual resin RESIACE Usage -60 Flute grinding for carbide drill, endmill, and PCD drill 0 100 200 300 400 500 600 Chipbreaker grinding for insert Bond Variation (C°) Other tool grinding (cylindrical grinding, surface grinding, etc.) Bond Variation Three types are available, depending on usage and conditions Bond Strength Special Features BRA10 Focus on sharpness  BRA20 Standard     BRA30 Focus on tool life13
  • 15. RESIACE Data /Water-soluble Coolant■ Grinding Test Conditions Work Material: Tungsten carbide Grinding Ability Wear Amount Specification: SDC140-100B Shift of Grinding Resistance Shift of Wheel Wear Amount Peripheral Speed: 1600m/min 60 80 : SDC140N100BRA30 (RESIACE) : SDC140N100BRA30 (RESIACE) : SDC140-100B (Current resin bond) : SDC140-100B (Current resin bond) Radius of Wheel Wear Rate ( m) Depth of Cut: 2mm 70 50 Outlined : Normal direction Feed Rate: 50mm/min Solid : Tangential direction 60 Grinding (N/mm) Coolant: Water soluble 40 50■ Results 30 40 Equivalent grinding ability 20 30 (grinding resistance) and 6 times 20 10 tool life (grinding ratio) compared 10 to current resin bond. Significant 0 0 improvement of interval for shape 0 1000 2000 3000 4000 0 1000 2000 3000 4000 correction is possible for flute Cumulative Amount of Material Removed (mm3/mm) The Cumulative Amount of Material Removed (mm3/mm) grinding of carbide drill or endmill. Data /Oil Based Coolant■ Conditions of Grinding Test Grinding Ability Wear Amount Specification: SDC140-100B Peripheral Speed: 1600m/min Shift of Grinding Resistance Shift of Wheel Wear Amount Depth of Cutting: 1mm 60 80 : SDC140N100BRA30 (RESIACE) : SDC140N100BRA30 (RESIACE) Feed Rate: 30mm/min : SDC140-100B (Current resin bond) Radius of Wheel Wear Rate ( m) : SDC140-100B (Current resin bond) 70 50 Outlined : Normal direction Coolant: Oil based Solid : Tangential direction 60 Grinding (N/mm) 40 50■ Results 30 40 RESIACE achieved significant 30 grinding ratio (about six times) by 20 maintaining superior grinding 20 10 ability, even in the range where 10 current resin bond shows signs of 0 0 excessive wear due to heat 0 1000 2000 3000 4000 0 1000 2000 3000 4000 deterioration. The combination of Cumulative Amount of Material Removed (mm3/mm) The Cumulative Amount of Material Removed (mm3/mm) grinding ability and shape maintenence makes flute grinding of carbide drill or endmill possible. Process Results Process Results Proces Result Process Results RESIACE Process: PCB flute grinding Diagram Evaluation: Interval of shape correction Results: Shape Maintenance Usual Reached 1 4 ~6 resin Times RESIACE 6 1 2 3 4 5 6 (Exponentiation) 14
  • 16. Grinding Resin Bond Wheel FluteMAX applies super heat resistant resin with a special filler to achieve both superior cutting ability and long tool life. Suitable for grooving applications such as endmills, drills, reamers, and creep feed grinding for various other tools. Super heat resistant resin helps to reduce deterioration under very high temperatures. al Excellent cutting ability and shape retention even for heavy load eci Sp tures grinding such as creep feed grinding. Fea High feed rate and long dressing interval compared to conventional items which leads to high efficiency and cost reduction. Comparison to Conventional Bond for Creep Feed Grinding of Carbide ■ Working Conditions Work Material Wheel Speed V=1,600m/min cemented carbide Speed for Work Material F=80mm/min Wheel Specification SDC140-100B D.O.C. a=0.5mm/pass 60 Results Normal Direction Grinding Force (N/mm) Grinding force of conventional bond suddenly Conventional increased and was interrupted due to burn, 50 while the FluteMAX kept low grinding force and maintained cutting ability. 40 30 20 10 0 ×100 0 2 4 6 8 10 12 14 16 18 20 22 Cumulative Stock Removal (mm3/mm)15
  • 17. Grinding Metal Bond Wheel Bond Wheel While resin bond combined with diamond or cBN wheel is ideal for low horsepower and low rigidity machines, it is unsuitable for high efficiency or long tool life grinding because of its low heat resistance. CBM Bond Wheel was created to exhibit excellent heat resistance of metal bond and surpasses the grinding ability of the resin bond wheel. Newly developed metal bond has both excellent grinding ability and provides long tool life. It also Characteristics increases grinding efficiency, especially when used with oil-based coolant. • • Flute grinding for endmills, drills, and reamers • Usage Chipbreaker grinding for inserts Heavy duty grinding of various tools, including special steel tools Recommended Usage Line Up Recommendation CBM-L To increase feed rate when flute grinding high speed steel or carbide drill CBM-P To increase tool life when flute grinding high speed steel or carbide drill Long CBM-P Flute Grinding CBM-L Tool Life Grinding Ability Good Bond Line Up17
  • 18. CBM Bond Wheel Comparison of Grinding Surface Grinding Resistance Comparison 160 N/mm →1) Wheel Specification 140 Partial wear confirmed Resin: SDC325N100B 120‚ CBM-L: SD325L100CBM 1002) Work Material Grinding Resistance 80 Normal Cemented Carbide processing 603) Conditions ● Wheel Peripheral Speed: 1500 mm/min 40 ▲ Resin Bond ● CBM-L ● D.O.C. : 3mm 20 ● Coolant : Oil-based 0 50 75 100 125 ● Machine: Horizontal spindle Feed Rate mm/min → surface grinder Resin Bond Comparison1) Wheel Specification Resin: SDC325N100B Comparison of Grinding Quantities 1500‚ CBM-L: SD325L100CBM Quantity Ground2) Work Material 1000 Cemented Carbide3) Conditions 500 ● Wheel Peripheral Speed: 1500 mm/min ● D.O.C. : 3mm 0 ● Coolant : Oil-based Resin Bond CBM-L CBM-P ● Machine: Horizontal spindle surface grinder Comparison of Grinding Resistance Comparison of Surface Roughness 60 1.5 Grinding Resistance N/mm Surface Roughness Ry m 40 1.0 20 0.5 0 0.0 Resin Bond CBM-L CBM-P Resin Bond CBM-L CBM-P 18
  • 19. Grinding Metal Resin Bond Wheel Hybrid Wheel The Hybrid Wheel was developed for high-efficiency processing of cermet, a material that is difficult to grind. Hybrid consists of metal bond and resin bond which offer excellent grinding ability. The incorporation of these two materials offer: • e xcellent grinding ability and long tool life due to an effective micro-segment of special metal bond • g ood surface roughness and minimal chipping due to resin bond matrix The Hybrid Wheel is a diamond wheel created to make cermet grinding easier. • M achining efficiency: more than double Characteristics • D ressing interval: more than double • T ool life: more than 1.5 times • S urface roughness: good  Main Usage • O uter grinding of cermet, surface grinding, surface honing, grooving and chipbreaker grinding, etc. • V arious grinding including cemented carbide and ceramics Micro-segment structure19
  • 20. Hybrid Wheel Type and standard size Straight Type Cup Type D D W X X T T H H Item Number D      T     X    H Item Number D      T     X    H HS050 50 HC050 50 HS075 75 HC075 75 3,5,8,10 HS100 100 HC100 100 As requested HS125 125 3,5,8,10, HC125 125 As requested HS150 150 15,20 HC150 150 HS175 175 HC175 175 3,5 HS180 180 HC200 200 3,5 HS200 200 HC250 250 5,8,10,15 HS250 250 HC300 300 HS300 300 HC350 350 HS350 350 10,15,20, HC400 400 HS400 400 25,30 HC500 500 HS500 500 All cup wheel types are available. HS600 600 ● Performance of Hybrid Wheel Size Hybrid Current resin bond 350×12W×6×, 6A2  When Ordering Wheel Please indicate the item Specification #325−75−HB SDC325R75B number and hole size (H) Work Size 12.7 × 3.175 when ordering.Material Specification TIC−TIN Cermet Machine TA outer grinder Peripheral Speed Special requests are also 1,600m/minGrinding welcome. Speed of Cutting (side) 3mm/minCondition Speed of Cutting (R part) 40mm/min Coolant Water soluble Current Value 9A 10A Dress Interval 300~400% 100% Result Processing Quantity 150~200% 100% Surface Roughness Good Good Chipping Good Good 20
  • 21. Grinding Metal Bond Wheel MT Bond Diamond cBN Wheels MT Bond is a new metal bond which is manufactured to reach optimum grinding ability, fusing the advantages of both resin bond and metal bond. The Diamond Wheel efficiently grinds ceramic, carbide, cermet, and quartz as well as other materials. MT Bond Wheel is recommended for the surface grinding with 6A2 cup wheel and the creep feed grinding by profiled wheel, which sustains its grinding ability. MT Bond Wheel--pursuing the ideal grinding wheel Fine Ordinary wheel MT Wheel Efficiency Accuracy MT10 and 20 are recommended for the grinding operation Surface Finish of various tools such as tungsten carbide, cermet, and high speed steel. MT30, 40, and 50 are recommended for the surface grinding of glass, various ceramics, and steels. Grinding Ability High Grinding Operations Ceramic Aluminum Oxide Surface grinding (horizontal spindle) Silicon Nitride Surface grinding (VSRT) Magnet Ceramic Silicon Carbide Double disc grinding Zirconium Flat face honing Surface grinding (VSRT) Aluminum Oxide Surface grinding (horizontal spindle) Ferrite Silicon Nitride Surface grinding (VSRT) Double disc grinding Neodium Magnet Silicon Carbide Double disc grinding Flat face honing Tooling Zirconium Flat face honing Surface grinding (VSRT) Ferrite Flute grinding Double disc grinding Neodium Nick grinding Flat face honing High Speed Steel Tooling Profile grinding Automotive Machinery Flute grinding Surface grinding (VSRT) Tungsten Carbide Flute grinding High Speed Steel Nick grinding Chipbreaker grinding Steel Casted Alloy Cermet Thread grinding Profile grinding Ceramic Sintered Alloy Double disc grinding Automotive honing Flat face Machinery Semiconductor Profile grinding e Surface grinding (horizontal spindle) Flat face honingde Surface grinding (VSRT) Surface grinding (VSRT) Tungsten Carbide Flute grinding Double disc grinding Steel Casted Alloy Magnet Silicon Chipbreaker grinding e Double disc grinding Double disc grinding Surface grinding (VSRT) Cermet Thread grinding Sintered Alloy Compoundm Flat face honing Flat face honing Surface grinding (VSRT) Semiconductor Profile grinding Flat face honing Ferrite Double disc grinding Double disc grinding Neodium Silicon Flat face honing Surface grinding (VSRT) Compound Tooling Optical Electronics Medicare Others Flute grinding Surface grinding (horizontal spindle) High Speed Steel Nick grinding Glass Surface grinding (VSRT) Profile grinding Finish on eye-glass lens edge Plasticsutomotive Machinery Crystal Double disc grinding Optical Electronics Quartz Flat face honing PVA Grinding Stone Dressing Medicare Others Flute grinding Surface grinding (VSRT) Surface grinding (horizontal spindle) Sapphire Curve generation Tungsten Carbide Chipbreaker grindinged Alloy Glass Surface grinding (VSRT) Cermet Double disc grinding Thread grinding Plastics Finish on eye-glass lens edge d Alloy Cylindrical grinding Crystal Double disc grinding Flat face honing Semiconductor Quartz Flat face honing Profile grinding Stone PVA Grinding Flat face honing Dressing Double disc grinding Sapphire Curve generation Silicon 21 Compound Surfacegrinding (VSRT) Cylindrical grinding
  • 22. MT Bond WheelMT10 • MT20 • MT30 • MT40 • MT50 Straight Style Cup Style Type D T X H Grit Size Concentration Type D W X H Grit Size Concentration 50 50 1A1 75 6A2 75 2~30 100 60 25 100 3A1 150 As specified 11A2 125 ~ ~ 3,5,7 200 3,000 125 150 14A1 250 12A2 175 60 25 3~30 300 200 As specified 3,5,10 As specified ~ ~ 400 11B2 250 3,000 125 300 6A9 350 400 6A2S 500 600 Specials can be designed and produced based on consultation. Data.1 ■ MT Bond grinding force is lower than resin bond 30 Comparison of grinding force of surface grinding of 25 silicon nitride Grinding Force (N/mm) 20 Workpiece: Silicon Nitride 15 Grinding Conditions Wheel Speed: V=1,760m/min 10 Work Speed: F =10m/min D.O.C.: a =20 m 5 0 Result The grinding force (normal force) is 40% #140-MT #140-B lower than the resin bond wheel. Data.2 ■ Finer grit reduces grinding force 200 Grinding force on creep feed grinding 150 Grinding Force (N/mm) Workpiece: Silicon Nitride Grinding Conditions 100 Wheel Speed: V=1,600m/min Work Speed: F =60m/min D.O.C.: a =1mm 50 Result MT Bond Wheel shows 20% lower grinding 0 force than resin bond wheel with the same #230-B #230-MT #400-MT #800-MT grit size. The finer grit produces a lower grinding force (comparison is between grit sizes #230, #400, and #800 US mesh). Data.3 ■ Grinding ability of MT Bonds 50 400 45 Fn´ 350 Ft´ The perfomance of MT Bonds on silcon nitride grinding 40 G.R. 300 35 Grinding Force (N/mm) 250 Grinding Ratio 30 Workpiece: Silicon Nitride 25 200 Grinding Conditions 20 150 Wheel Speed: V=1,650m/min 15 Work Speed: F =10m/min 10 100 D.O.C.: a =20 m 50 5 0 0 MT50 MT40 MT30 MT20 MT10 22
  • 23. Grinding Vit Metal Bond Wheel CP Wheels The grinding of PCD-PCBN, both extremely difficult- to-grind-materials, results in high wear on the grinding wheel and longer grinding time because they grind against each other between the super abrasives. A.L.M.T.’s solution is CPV, which increases efficiency by shortening grinding time, and CPM, which reduces tool costs by extending tool life. A suitable wheel can be selected based on the specifics of an operation. Chipping Size on Cutting Edge CPV and CPM can be applied to rough and finish grinding by selecting grit size in accordance to required limit of Wheel Shape chipping. Chipping Size on Cutting Edge CPV and CPM can be applied to rough D and finish grinding by selecting grit size W in accordance to required limit of X chipping. PCD T H ød For Efficient Grinding CPV CPV Advantage The combination of efficient dressing and higher grinding ability results in overall shorter grinding time. 120 Dressing Time CPV Advantage 100 The combination of efficient dressing and Grinding Time higher grinding ability results in overall shorter Grinding Time (Sec) 80 grinding time. 60 40 20 0 CPV CPM23
  • 24. CP Wheel For Longer Lasting Grinding Operation CPM CPM Advantage Under the same conditions, CPM increases the grinding ratio, as well as extends tool life and reduces tool costs. 25 (×10-3) 20 15 Grinding Ratio Gr 10 5 0 CPV CPM■ Standard Dimensions for CPV CPM Wheel Machine Depth of Type Outer Dia. (D) Width(W) diamond layer(X) Bore dia. (H) Setting hole(PCD) 5 CPG 10 150 10以下 40 4-?6.8キリ 15 Ewag 20 5 10 125 10以下 31.75 なし 15 Makino 20 5 10 150 10以下 38.1 なし 15 20 5 10 Waida 200 10以下 60 4-ø8.5キリ 15 20 Please inquire about special dimensions 24
  • 25. Grinding Vitrified Bond Wheel VITMATE Features High accuracy and efficiency grinding with VX bond for longer wheel life and exceptional grindability High holding power with cBN grain Controllable dressing ability for required surface roughness and grinding speed Multiple combinations of porosity and bond grades for a wide range of applications Running Conditions Applications O.D. ø3∼750mm Industries: Automotive, bearing, household Thickness 3∼300mm appliances, tools, machinery, gears, mold die Width 2∼15mm Work piece: Cam, crank shaft, injection needle, Spec. cBN (#60∼#2000) rocker arm, compressor, bearing, ball screw, motor 2 times dressing interval for compressor component Data1. Piece Material: Compressor component, SCM415(HRC62) Stock Removal: O.D. = 0.28 End Face = 0.15mm End Face Grinding ■ Application Example 1. Machine : Angular grinder 2. Wheel :350D-22U BN120N175VX5 3. Dresser :Diamond rotary dresser SD40M O.D. 4. Conditions : Grinding Peripheral speed = 80m/s Work rotation = 320 rpm Stock allowance = O.D. 0.28mm End Face 0.15mm Coolant emulsion = 5% ■ Results Conventional VITMATE Efficiency Roughness 5.0 mRmax 3.2 mRmax 56% improved Grinding time 40sec 30sec 25% improved Dressing interval 400 pcs. 800 pcs. Operating rate increased Wheel life 70,000 pcs. 140,000 pcs. Wheel life extended25
  • 26. VITMATE UNIMATE UNIMATE Features Uniform performance over the entire perimeter of wheel by ring integral molding and sintering of cBN layer Improved trueing accuracy, especially with formed diamond rotary dresser Dramatically improved coolant holding and less grinding burn Running Conditions Applications O.D. ø3∼750mm Industries: Automotive, bearing, household Thickness 3∼300mm appliances, tools, machinery, gears, mold die Width 2∼15mm Work piece: Cam, crank shaft, injection needle, Spec. cBN (#60∼#2000) rocker arm, compressor, bearing, ball screw, motorHigh accuracy grinding by integral molding core Data1. Workpiece: Inner race of CV joint ■ Application Example 1. Machine : Surface grinder 2. Wheel :126D-23U BN100N150VX4A 3. Peripheral speed :46m/s 4. Table feed : 600mm/min ■ Results 1. UNIMATE : 0.8-2.0Ra Requirement : 2.5Ra 2. Dressing interval : 25% extension Dressing Interval 40 Pieces 30 20 10 0 Conventional UNIMATE 26
  • 27. Grinding Vitrified Bond Wheel HiG-V Features High speed grinding wheel for over 60m/s High grindability and safety with selected core Amazing productivity Long lasting quality and satisfactory surface Running Conditions O.D. ø100~500mm Applications Thickness 5~50mm Industries: Automotive, bearing, machine tool Width 3~6mm Application: High speed grinding Spec. cBN(#60~#325) Work piece: Cam, crank shaft, turbine blade For high speed contour grinding ø37 ø35 ø45 ø60 200 Data1. Material: Hardened bearing steel (HRC=60) ■ Application Example ■ Results 1. Machine : High speed grinder 1. Surface roughness: 40% improved 2. Wheel :400D-10U 2. Dressing interval: 5.5 times lengthened BN60M200VX2 3. Dresser life: lengthened by less dressing 3. Peripheral speed = 160m/s 4. Wheel cost: 80% reduced 4. D.O.C. = 0.2mm/diameter 5. Wheel Feed = 300 mm/min 6. MRR: Z’ = 180mm3/mm/s Surface Roughness Dressing Interval Wheel Cost Surface Roughness (Rz m) 1.8 750 550 1.4 m 100 1.4 500 100 1.0 m 1.0 100 20 100 0 0 0 HiG-V Conventional HiG-V Conventional HiG-V Conventional27
  • 28. HiG-V EG Wheel EG Wheel Features Easy dressing and trueing on a grinder with special diamond rotary dresser Excellent run-out and form accuracy in short time on a grinder No special unit, technology, or skill required Accurate arrangement of cutting edges for surface roughness, productivity and wheel life Applications Running Conditions Industries: Machine tool, household appliances, O.D. ø3~750mm automotive, bearing Thickness 3~300mm Work piece: Ceramics and carbide Width 2~15mm Spec. cBN(#80~#3000)Good surface roughness, high productivity, and longlasting quality 60 360 Data1. Material: Ceramics post Alumina 60×360L ■ Application Example 1. Machine : Okamoto surface grinder PSG-63DXNC 2. Wheel : 300D-15U 1) #270 resin bond wheel 2) SD230G100C3 Surface Roughness 3. Rotary Dresser : 150D-10U Accuracy Straightness SD40-M 4. Dresser Drive Unit : SGS-50 (ALMT) 4.0 Micron m) 3.0 ■ Results ( 1. 6 times productivity than conventional 2.0 diamond resin bond wheel 1.0 2. Dressing from trueing from 60 min. to 5 min. 0 EG Wheel Conventional 28
  • 29. Grinding Metal Bond Wheel Double disc metal bond wheel for electro-discharge trueing MB Spark was developed to meet the needs of surface quality improvement of elements used in automotive and household appliance in the progress of energy saving and miniaturization. MB Spark changes the world of double 1. etal bond wheel with M disc grinding by improving the trueing interval over a excellent electro-discharge conventional resin bond grinding wheel, in combination ture s trueing capability. Easy with electro-discharge trueing. Fea high-accuracy trueing on a grinder. 2. ong lasting cutting performance and L high-wear resistance. 3. ess industrial waste--stops sludge L produced from grinding wheel during trueing. The next generation of double disc grinding systems Long Lasting Quality MB Spark has higher wear Workpiece: resistance than conventional resin ■ Comparison of Grinding Capability Oil pump component 40 bond wheel and keeps flatness of Super Abrasive Layer Wear ( m) Trueing super abrasive layer longer. No 35 Limit frequent trueing interval is suitable 30 for automated production line. 25 20 15 Resin bond wheel 10 SPARK 5 0 0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 # of Pieces ■ Application Air conditioner component Oil pump component Engine component29
  • 30. MB Spark3 times the wheel life ofconventional resin bond wheel. High Trueing Performance • Shorter work time grinder; quick trueing with on high accuracy using special low-melting metal bond suitable for electrodischarge trueing. • Discharge Electrode Machine: Koyo Machinery F urther benefits are attained with the fine super-abrasive Electro-discharge trueing for excellent flatness acquired in a short time frame. ■ Comparison of Trueing Performance 40 WA trueing 30 Trueing Time (min.) 20 Electro-discharge trueing 10 Resin bond wheel SPARK #140-B #230-MED■ Grinding Example High GrindabilityGrinder Koyo KVD-300 Excellent cutting performance with a ø305D-75W-3X-ø80H rigid metal bond suitable for doubleGrinding Wheel MB Spark #230-MED disc grinding, which has high retention Resin bond wheel #140-B of super abrasiveness due to electro-Workpiece Oil pump component discharge trueing. Powermetal SMF4040Condition Displays ability to work in the same Upper:1500min-1(C.C.W)Wheel Rotation tough conditions as a conventional Lower:1500min-1(C.C.W) bond wheel.Total Stock Amount 0.2mm (both sides) 6 Load Current Value ofRough Stock 0.19mm (both sides) Grinding Spindle (A)Rough Grinding Speed 0.035mm/sec Resin bond wheel 4Finish Stock 0.01mm (both sides) SPARKFinish Grinding Speed 0.015mm/sec 2Spark out 2sec 0 0 20 40 60 80 100 120 Grinding Amount (cm3) 30
  • 31. Grinding Vit Metal Bond Wheel Divisible Cassette Diamond/cBN Lapping Plate DPG Wheel 1 Environment Replace lapping with environmentally friendly, fixed 2 High Efficiency abrasive diamond pellet grinding. 1) Reduce industrial waste dramatically 2) Low Production with chloric organic solvent 3 No clean-up Cost 3)1Clean operating environment Environment 4 Process Reduction ■ Grindability of MDP Bond 21High Efficiency Environment Grinding speed 5 to 100 times as fast as loose 3 Low Production abrasive lapping. Grinding Speed 21HighCost Efficiency Environment Grinding ratio 10 4 Process 3 Low Production Reduction 8 2 HighCost Efficiency Reduce maintenance costs with long lasting plate 6 4 Process Index and Reduction gear. 3 Low Production Cost 4 2 4 Process Reduction 0 MDP1 Integrate pre-grinding and lapping in one process MDP2 MDP3 MDP4 MDP5 Grinding Speed ( m/min) 0.25 100 Surface Roughness (Ra m) ■ Cassette Plate Surface Roughness (Ra m) 0.2 Grinding Speed ( m/min) 80 Pin Hole Top Face 0.15 60 0.1 40 20 0.05 0 0 Diamond Pellet Lapping DPG31
  • 32. DPG Wheel Example application Superior Fine Grain Metal bond wheel Vitrified Bond Wheel MDP Series (rough grinding) VDP Series (finish grinding) Workpiece: Alumina ø80-5T-ø70H Workpiece: Tool Steel ø20-3T Wheel Specs: 9B SD400-MDP4 Wheel Specs: 9B SD2000-VDP3 Conditions Conditions 1)Top Plate: 7min-1 1)Top Plate: 50min-1 2) Bottom Plate: 20min-1 2) Bottom Plate: 50min-1 3) Sun Gear: 9min-1 3) Sun Gear: 10min-1 4) Internal Gear: 7min-1 4) Interal Gear: 0min-1 5) Grinding Pressure: 15KPa 5) Grinding Pressure: 200KPa 6) Coolant: ODIAP (2%) 6) Coolant: ODIAP (2%) 70 16 Grinding Speed m/min) 60 14 Grinding Speed ( m/min) 12 50 15 times 60 times ( 10 40 8 30 6 20 4 10 2 0 0 Lapping DPG Lapping DPG 0.6 2.5 0.5 2 Equal Flatness m) 0.4 Equal ( 1.5 TTV m) 0.3 ( 1 0.2 0.5 0.1 0 0 Lapping DPG Lapping DPG Size Max. Dia. Min. Dia. Easy change of plate 4B 299 117 ■ No detaching base plate 5B 389 213 ■ Divisible cassette fixed on base plate 6B 380 148 ■ Short dressing time 6B/9B 650 384    (9B = 20 minutes, less than 2 hours for 16B) 9B 637 218 Pellet pattern keeps high grinding accuracy 12B 1058 360 13B 950 274 ■ Divisible cassette designed for pellet layout 15B 1022 346 ■ Seams never interfere with the density of pellet distribution 16B 1127 270 18B 1260 294 20B 1355 458 Free layout of coolant hole for top plate 24B 1592 554 ■ Coolant pool on clamp face 28B 1864 660 *Special sizes also available 32
  • 33. FluteMAX age Us Grooving of endmills, drills and reamers Breaker grinding of inserts Heavy grinding of various tools including special steel tools e Typ Bond Strength Special Feature 3 different L Superior cutting ability N Standard bond types P Superior shape retention Flute Grinding of Cemented Carbide Endmill■ Working Conditions Work Material Wheel Speed V=1,600m/min 8D 2-flute endmill a=1.5mm (1st time) Wheel Specification SDC270-100B D.O.C. 0.5mm (2nd time) Results Compared to conventional items in the market FluteMAX can increase feed ratio by 4 times and 350 has same dress interval life. 300 Feed Ratio (mm/min) 250 200 150 100 50 0 Conventional 16
  • 34. Grinding For Semi-conductor Nanomate V-Heart Nanomate V-Heart which consists of strong holding diamond grit and high porosity vitrified bond, combined with a specially-shaped diamond layer, offers lower grinding force, creating a new field for grinding operations. Nanomate has a flatness of less than 1µm on ø300 wafer and makes difficult-to-grind weak and brittle materials, including semi-conductor, electronics, and other materials. Lower grinding force, shallower affected layer Grinding Force Low grinding forces result in reduction of each Grinding force is 1/10 of load applied on workpiece and grinding machine. Grinding resin bonding wheel Force ン Resin High ジ レ Resin bond High ル メタ Special metal 特殊 ナノメイト Grinding Force Nanomate V-Heart Continuous Low Stock Removal Increase Grinding 2000 4000 6000 8000 Grit Size F-Star Super-fine diamond grit and super-fine ceramics revolutionized the conventional wisdom with regard to grinding wheels. Application of both acquired material technology and production technology has allowed super-fine grinding. Its effectiveness to reduce a grinding damaged layer of brittle material such as polish-reduction of ø300mm silicon wafer and prevent cracks on a thin layer device wafer. ■ Grain size/surface roughness Super-fine diamond grain and super-fine ceramics General purpose High precision open the door to advanced technologies. grinding machine grinding machine 50 10 PV(nm) Ra(nm) ■ PV(nm) ■ Ra(nm) 45 9 40 8 35 7 PV (nm) Ra (nm) 30 6 25 5 20 4 15 3 10 2 5 1 0 0 3000 5000 8000 Grinding result by SD8000 Nanomate (mesh)33
  • 35. CMP Conditioner For Semi-conductor Diversifying the CMP process 1 High quality diamond Scratches caused by diamond crash can be minimized More uniformity of the diamond grit shape and stable performance 2 High precision core material Uniform contact with the conditioner 3 High precision electro-plating Perfect single diamond layer Uniform distribution of the diamond grit creates the best surface condition of the pad and stable lapping performance 4 Dedicated production line CMP Conditioner is produced on a line isolated from other tools Long life due to optimizing the shape of the abrasive grain layer ALMT NS-2 ALMT NS-2 Pad Pad Cut Rate Conventional Conventional conditioner Pad Conditioning Time CMP Conditioner correspondsCMP Condtioner to ø300mm wafer Correspond to CMP Pad Conditioner for ø300mm High grinding ability for the dressing operation of CMP Pad ø300mm wafer. Features 1. xcellent precision of the tool core processing and E electroplating results in high grinding performance 2. Long lasting grinding performance 3. djustable when required due to the unique shape A of the diamond layer Adjustment cutting rate is possible with various selections of diamond abrasive 200 Sharp Pad cut rate( m/h) 150 Blocky 100 50 0 Sharp Blocky 34
  • 36. Diamond ToolsRotary Dressers Rotary Dressers Super-fine diamond grit and super-fine ceramics revolutionized the conventional wisdom with regard to grinding wheels. Application of both acquired material technology and production technology has allowed super-fine grinding. Its effectiveness to reduce a grinding damaged layer of brittle material such as polish-reduction of ø300mm silicon wafer and prevent cracks on a thin layer device wafer. 35
  • 37. RZ TypeAdvanced technology in high precisionelectro-deposition allows any type SZ Typeof profile can be produced. The highconcentration of diamond grit isarranged randomly and made by thereverse platingZmethod, so it is also Typesuitable for longer life applications.Various optional specifications are also RZ Typeavailable. SX Type SZ Type X TypeA rotary dresser with diamond gritarranged regularly made by the reverse Z Typeplating method. Concentration of thediamond can RZ controlled according be Typeto requirements. The SZ Type provides SX Typeefficient plunge dressing of large sizerotary dressers. Type SZ X Type Z TypeThe Z Type rotary dresser has diamond RZ Typefixed directly to the surface of the body SX Typethrough plating. This type can be maderelatively easily and is suitable for small SZ Typelot production and trial production. X Type Z Type RZ Type SX TypeA rotary dresser Type diamond grit SZ witharranged regularly made by the X Typereverse powder metallurgy method.This type works very efficiently in Z Typegrinding applications that require sharpcut of grinding wheels. It can also beeffective in traverse dressing and SX Typecontour dressing. X TypeX Type rotary dresser is a metal bondtype interfused with diamond particles.High performance is made possibleby free selection of concentration anduniform distribution of diamond grit. Thistype is suitable for transverse dressingof our VITMATE and EG Wheel. 36
  • 38. Diamond ToolsRotary Dressers Manufacturing Details Ranges for Rotary Dressers ■ Details RZ SZ Z SX X Manufacturing Electro-plating Sintering Sintering Electro-deposition Method Diamond Grit Random Regular Random Random Regular Distribution Applicable #20~#140 #16~#20 #30~#140 #16~20 #30~80 Grit Size       Complex Cup Profile Form Form Form Fine Straight   Dress Plunge Plunge Plunge Plunge Traverse Method Traverse Traverse Internal Bearings Shafts Gear Grinding Turbine Blades Major Grinding Applications Injection Camshafts Centerless Needles Grinding Geometrical Accuracy - Surface Roughness Dressing Force Highest precision Any Large diameter Gear grinding Consistant concentration Major Fine profile dressing ability settable Features Complex profile High dressing ability ■ Ranges 50 100 150 200 250 300mm O.D. ø50~ø230 RZ Type Width 200 O.D. ø50~ø230 SZ Type Width 250 O.D. ø10~ø300 Z Type Width 250 O.D. ø20~ø180 SX Type Width 150 O.D. ø20~ø300 X Type Width 150 *Specials available upon request 37
  • 39. Outline of Production Processes for Rotary Dressers Electro-deposition Electro-plating Sintered Method Method Method RZ・SZ Type Z Type SX Type Reverse Plating Diamond is fixed Powdered Method directly on the body Metallurgy As the product is and finished by lapping Method processed under room on the surface. Surface of the diamond temperature, the layer is lapped in the accuracy is not final process to achieve changed by thermal specified accuracy. expansion. Diamond Setting Machining Body Diamond Setting Plating 25°C Sintering 1000°C (+) Diamond Body Setting Body Machining Body 0.03mm Machining Body Control Grinding Control Grinding0.002mm 38
  • 40. Diamond ToolsRotary Dressers Tolerances on Rotary Dresser Designs W U U Value (mm) W Value (mm) RZ Type ≥10 RZ Type Z ≥0.5Z SZ Type ≥10 SZ Type ≥0.5Z SX Type ≥3 SX Type ≥4Z Z Type ≥3 Z Type ≥4Z X Type ≥3 X Type ≥2Z M Y Value (mm) M Value (mm) RZ Type ≥10 RZ Type ≥L L SZ Type ≥10 SZ Type ≥L SX Type ≥4 SX Type ≥0.5L Y Z Type ≥4 Z Type ≥0.5L X Type ≥4 X Type ≥0.5L Convex R Convex R Concave R Concave R *Convex R Value (mm) *Concave R Value (mm) RZ Type ≥0.1 RZ Type ≥0.03 SZ Type ≥0.2 SZ Type ≥0.15 SX Type ≥0.2 SX Type ≥0.15 Z Type ≥0.3 Z Type ≥0.3 *Value depending on diamond grain sizes. P P P P Value (mm) RZ Type ≥0.3 39
  • 41. Accuracy of Rotary DressersItem Factor Symbol Accuracy (mm) Illustration Runout 0.002 Profile 0.005 A L L Width L ±0.005 S Radius R ±0.002 0.002 R R R Step S ±0.001Profile Outline 0.002 0.002 Angle ±2´ nP Straightness 0.002 P P P Pitch P ±0.002 Accumulative nP ±0.004 Pitch Bore H +0.005 −0 0.002 Profile 0.002 A Parallelism 0.002 ControlBody 0.002 Profile Squareness   0.002 A Runout 0.002 H Other tolerances available upon request 40
  • 42. Diamond ToolsRotary Dressers Optional Specifications of Rotary Dressers Optional Specifications for RZ Type (reverse plating) 1. Improved Dressing Ability (for fast dressing) GB Type (controlled diamond concentration) Even for electro-deposition type which the diamond concentration is difficult to contol, lower concentration is easily attainable for faster dressing by setting glass balls in the diamond layer. Sharp Type (controlled diamond projection)  By a unique process that does not etch into the bond layer, diamond projection is controlled freely without pull-out of the diamond grit. Cross Ditch (controlled diamond concentration)  Improves the evacuation of chips and coolant. ■ Cross-ditch Surface and Shape 120 Grinding (exponential) 100 80 60 40 Standard GB Sharp Cross Groove 2. Improved Wear Resistance (for longer life) Strong Type  Peak of convex shape, which is easily worn out, is reinforced by setting pre-shaped diamond to hold accuracy and wear resistance. 41
  • 43. Optional Specifications for SX Type 3. For Improving Wear Resistance High Concentration Type By the unique pattern of diamond setting, the number of diamond cutting edges is increased to a maximum of 100pcs/cm2, and provides longer tool life. Strong Type The peak of convex shape, which is easily worn out, is reinforced by setting pre-shaped diamond in order to hold accuracy and wear resistance. Optional Specifications for Vitrified cBN Wheels (SP Type) 4. For stable performance and longer lasting sharpness SP RZ-SP and SX-SP are available and are suitable 1000 for the dressing of vitrified cBN wheels and other 800 high hardness abrasive wheels, where high wear Dress Ratio resistance on the profile of the rotary dressers is 600 required. 400 200 0 Standard SP Polycrystalline Prism Diamond The Crown Dresser, made by arranging isotropic polycrystaline Dressing Example ■ prism diamond, provides stable tool life and performance, solving the problem of short tool life and instability caused Target Dresser by un-isotropy and cleavage, which are characteristic of Mono- crystalline Polycrystalline mono-crystal diamond. Dressing Conditions Wheel specs: CBN230G125V3 ø30×20×5 1200min-1 RD specs: 0.4 2L 25pcs ø25×18 250min-1 Testing Instrument: TOOLMEX Feed Rate: 240mm/min Dressing Amount: 0.002mm/pass (Total 1.0 mm in 500 dressing cycles) Results Wear Volume 100 50 0 Mono-crystalline Polycrystalline 42
  • 44. Diamond ToolsRotary Dressers Inspection of Rotary Dressers For higher accuracy... Required accuracy of rotary dressers is becoming more strict, ranging from microns to submicrons. To ensure required accuracy, we have established an excellent inspection system with the most up-to-date equipment. Description of Inspection ■ Inspection with transfer test pieces 1. Measuring dimensional accuracy and profile ………tool microscope, profile measuring equipment, projector 2. Surface roughness……surface roughness meter ■ Body accuracy 1. Bore………………..............…air micrometer 2. Parallelism, squareness .....................roundness measuring equipment 3. Reference surface (controlø) runout .....................roundness measuring equipment 4. Profile runout......roundness measuring equipment ■ Slip Test Results An inspection sheet showing measurements taken by the transfer test is attached. Rotary Dresser Coupon Coupon Inner diameter (Plate) (Cylindrical) Air micrometer Runout-reference surface Roundness measuring equipment Profile Tool microscope Runout-profile Profile measuring equipment Profile Roundness Projector Tool microscope measuring Profile measuring equipment equipment Projector Surface roughness Surface roughness Surface roughness meter Surface roughness meter 43
  • 45. Recommended Dressing Conditions■ Plunge Dress Conventional Grinding Wheel Hard Conventional Grinding Wheel cBN Wheel Dress Direction Down Down Down Peripheral Speed Ratio 0.25~0.5 0.3~0.9 0.3~0.9 Dress Amount 0.02~0.03mm 0.02~0.03mm 0.01~0.015mm Infeed Rate 0.5~1 m/rev. of wheel 0.1~0.5 m/rev. of wheel 0.01~0.5 m/rev. of wheel Dress Out 0~3 sec. 0~3 sec. 0~3 sec.■ Traverse Dress Conventional Grinding Wheel Hard Conventional Grinding Wheel cBN Wheel Dress Direction Down Down Down Peripheral Speed ratio 0.25~0.5 0.3~0.9 0.3~0.9 Dress Amount 0.02mm 0.02mm 0.01mm Depth of Cut 0.005~0.03mm/pass 0.003~0.005mm/pass 0.002~0.003mm/pass Dress Out (Traverse cycles) 0~4 times 0~4 times 0~4 times Feed Rate 80~140mm/min See below See below *RD= Rotary Dresser  Feed Rate Vr (RD peripheral speed) = RD revolution (min-1) × RD O.D. × π Down Dress Up Dress Vs (grinding wheel peripheral speed) = grinding wheel revolution (min-1) × O.D. × π Vr peripheral speed ratio = Vs Operation    C Feed rate = C×RD width × grinding wheel revolution Standard    0.025~0.1 Efficient grinding 0.125~0.2 Centerless 0.005~0.01 44
  • 46. Diamond ToolsRotary Dressers Technical Data In dressing, the surface roughness of grinding wheels is influenced by elements such as: Peripheral speed ratio (Vr/Vs), infeed per revolution of wheel (Ar), and dress out (Na). Peripheral Speed Ratio I Influence of Peripheral Speed Ratio on Grinding Wheel Surface Roughness Control of the grinding surface accuracy by up-dress is easier than by down-dress Higher feed rate creates more open grinding surface (grinding ability increases). 15 Surface Roughness of Grinding Wheel ( m) Test Conditions Grinding Wheel WA60K 10 Rotary Dresser #20/30 Grinding Wheel Peripheral Speed Vs=29m/s Dress Out Na=0 5 Infeed per rev. of grinding wheel Down Up Ar=0.18 m/rev Dress Dress 0 =0.36 m/rev 1.5 1.0 0.5 0 -0.5 -1.0 -1.5 =0.54 m/rev Peripheral Speed Ratio (Vr/Vs) =0.72 m/rev Influence of Peripheral Speed Ratio on Dressing Force Larger peripheral speed ratio allows higher Tangential force shows the same tendency normal force (increase in grinding ability). as normal force, but the value is much smaller. 8 0.6 0.5 Normal Force (N/mm) 6 Normal Force (N/mm) 0.4 4 0.3 2 0.2 0 0.1 1.0 0.5 0 -0.5 -1.0 1.0 0.5 0 Peripheral Speed Ratio (Vr/Vs) Peripheral Speed Ratio (Vr/Vs) 45
  • 47. Infeed Rate Influence of Infeed Rate of Grinding Wheel Surface Roughness (Na= Dress out wheel rotation frequency) Down Dress Na=0 Surface Roughness of Grinding Wheel ( m) 10 Higher feed rates create a more open grinding surface (grinding 8 ability increases). 6 Up Dress Na=0 Longer dress-out time diminishes Down Dress Na=80 4 sharpness of the grinding surface Up Dress Na=80 2 0 0.18 0.36 0.54 0.72 Infeed Rate ( m/rev) Influence of Infeed Rate on Dressing Force Larger feed rate increases normal force (grinding Tangential force shows the same ability increases). tendency as normal force, but the value is much smaller 6 0.5 Down Dress Vr =0.81 n- Vs Tangential Force (N/mm) 1 mi 00 Normal Force (N/mm) 5,0 0.4 4 0.3 in-1 Down Dress Vr =0.16 1,000m Vs 0.2 2 5,000min-1 Up Dress Vr =0.81 Vs 0.1 0 0 0.18 0.36 0.54 0.1 0.2 0.3 0.4 0.5 0.6 Infeed Rate ( m/rev) Infeed Rate ( m/rev) Dress OutInfluences of Dress out on Grinding Wheel Surface Roughness 12 Surface Roughness of Grinding Wheel ( m) Longer dress out time increases roundness of 10 the grinding surface, but reduces sharpness. 8 6 4 Down Dress Up Dress 2 0 80 150 240 320 Grinding Wheel Revolution During Dress Out (rev/sec) 46
  • 48. Grinding Rotary Dresser Small Size/High Performance Straight Type Straight Type Model Number S40-N S40-C S40- 6 6 6 Profile 10 +0.005 10 +0.005 10 +0.005 0 0 0 40 40 40 Diamond Natural Diamond CVD Prism (Crown) Synthetic Diamond Grit Size 40SPC 0.4×0.4 SD#40 Concentration 60 pcs/circumference 90 pcs/circumference 3.3ct/cm3 Cup Type Cup Type Model C40-N C40-C C40- Number 18 18 18 Profile 15 +0.018 15 +0.018 15 +0.018 40 40 40 0 0 0 Diamond Natural Diamond CVD Prism (Crown) Synthetic Diamond Grit Size 40SPC 0.4×0.4 SD/40 Concentration 40 pcs/circumference 90 pcs/circumference 3.3ct/cm3 Other sizes and specifications available upon request.47
  • 49. Crown DresserCrown Dresser ■ Features 1. Binderless CVD coated diamond is capable of high resistance, like monocrystal diamond. 2. Constant and stable active area with diamond column. 3. Cost effective with no reworking. 4. Optimized dressing performance is a result of diamond column size and distribution.Straight Type T Size CVD Size Pitch D ø35~180 0.2 ,0.4 , D H ø8~30 0.8~2mm 0.6 ,0.8 T 6~20 H Cup Type D Size CVD Size Pitch D ø40~80 0.2 ,0.4 , T H ø10~20 0.8~2mm 0.6 ,0.8 T 15~20 H Please contact us for special sizes. CVD Ace Dresser L L1 D W CO .5 45L 1.8 (mm) T 4 L L1 D W T 20° 45° 50 38 11 10 9 Please contact us for special sizes. Diamond Disc Dresser Worm wheel gear grinding with high accuracy 48
  • 50. Diamond ToolsMonocrystal Precision Cutting Tools 49
  • 51. A.L.M.T. Corp. has succeeded in making increasingly dominant precision diamond-cutting tools using our unique tool designs and ultra- precision machining technology without impairing the material’s excellent practical characteristics. We will guide you through a new stage of cutting technology that includes our vision of High Output, High Productivity, Environment and Nano- Definition, Ultra Precision, and High Accuracy. We hope that you will be pleased with the revolutionary change brought about by the Ultra Precision Cutting Tools of A.L.M.T.Material Characteristics of Diamond Knoop Hardness (N/mm2) Thermal Conductivity (W/m . C°) 1500 1300 104 100 ・C°) 1000 (GPa) W / (m 50 560 50 500 23 17 16 200 110 4 4 0 0 Single Polycrystaline cBN Cemented Alumina Single Polycrystaline cBN Cemented Alumina Crystal Diamond Carbide Crystal Diamond Carbide Diamond Diamond *The charactersitics of diamond are ideally suited for the requirements of cutting tools due to its exceptional hardness and low thermal conductivityDiamond Type and its Manufactured Products Graph demonstrates smoothness of machined workpiece Single by conventional tools and our newly developed tools. Crystal UPC Single Crystal Diamond New-D ◆ Polycrystalline Diamond e-Edge ◆ New-D Diamond Polycrystalline Diamond Polycrystal PCD Reamer Cemented Carbide Tool PCD Endmill PCD Circular Saw PD Coat 0 0.05 0.1 0.5 1.0 5.0 Unit: mRa Machined Surface Roughness 50
  • 52. Nano/Microforming Tools A.L.M.T. Corp., as a leading manufacturer of ultra-precision diamond cutting tools offers a broad range of nano- and micro-forming cutting tools to satisfy market needs. Our many years of experience and know-how have provided us with a comprehensive understanding of the optimal physical properties of mono-crystal diamond. Our state-of-the-art development process yields the highest precision in tool edge measurement. As a result, our diamond cutting tools achieve high-precision microscopic cutting in workpieces with nanometer requirements. Extremely sharp cutting edge with advance51
  • 53. Checking the variation in the distance between carbon atoms in single crystal diamond assists in determining the optimal crystal orientation. Measuring Technology Used for Diamond Selection The pursuit of producing nanometer-accurate Anisotropy of the atomic distance diamond cutting tools begins with the selection of optimal mono-crystal diamond. Although it is known that the lattice constant a a a of diamond is 3.5667Å the distance between the crystal planes in single crystal diamond a 2 a 2 varies, causing contamination or divisibility. 2 a 2 a 2 a 2 2 a 1 a 2 a 12 X-ray photography of Therefore it is very important to select the 4 4 3 a 4 single crystal diamond best diamond ore and determine the optimal (100) (110) (111) crystal orientation based on the application. Diamond Lattice Model Tool edge polishing technologies used for profiling under nanometer tolerances In order to accurately produce nanometer- controlled movement on a workpiece, a cutting tool requires a sharp Waviness cutting tool edge 44.5nm capable of producing 250nm nanometer-sized chips, 45° 125nm 45° in addition to high 22°30′ 0 125nm 22°30′ Cutting edge shape contour precision. We 250nm have achieved this using Polishing and Measuring Technology our unique polishing and measurement technologies. Manu. No. Window Angle 90°00′ Corner Radius 0.052mm 500nm Corner Height 4.120mm Sharply polished monocrystal diamond Extremely fine chips measured down to nanometer dimensions Contour inspection sheet Straightness and surface roughness unobtainable with photolithography or ion- beam method Nano-cutting and Micro-cutting Technology With its extremely sharp cutting edge, the UPC-Nano Series developed by A.L.M.T. Corp. achieves excellent surface roughness and straightness, which cannot be obtained using photolithography or ion-beam methods. 4 m They are also effective tools in high aspect-ratio Width of 15 m tip of Nano endmill applications where micrometer precision is required. 100 med UPC cutting tools Polished surface shown in the same magnfication Molds surface by microforming 52
  • 54. Cutting Nano Microforming Nano/Microforming Tools With their extremely sharp cutting edge, the UPC- Nano Series developed by A.L.M.T. Corp. achieves excellent surface roughness and straightness, which cannot be obtained using photolithography or ion- beam methods. They are also effective tools in high aspect-ratio applications where micrometer precision is required. Straightness and surface roughness unobtainable with photolithography or ion-beam method - Nano groove - Nano endmill - Nano ballendmill UPC-nano edge 10 m 10 m 5 m for ultra fine grooving W ±0.0005 60 L 45° 45° 0° 30 , 8 30 , 0° A 8.5 ° Application 1. Hologram diffraction grating 2. Straight fine grooving 3. LCD display optical waveguide Features 1. Grooving of the world’s smallest byte width (0.9 m) 2. World’s highest accuracy (±0.5 m) 3. Durable cutting tool edge achieved by high precision polishing 4. Extremely fine grooving, unobtainable with photolithography or ion-beam cutting53
  • 55. UPC Square type 50 øA ±0.01 ø6 0°±1° 45° B (0.5) (1) 5 ° G 16 Detail drawing the blade (100/1)Applications Features 1. Hologram diffraction grating 1. World’s smallest class groove width (30 m) achieves flexible 2. Fine grooving of free curves grooving such as curving 3. LCD display optical waveguide 2. World’s highest dimensional tolerance (2.5) 4. Microscopic machine part cutting 3. Durable cutting tool edge achieved by high-precision polishing 4. Extremely fine grooving, unobtainable with photolithography, etching, or ion-beam cutting Ball-end type 0~0.005 50 20° ø6 15° 30° Win do wA ng R is the center and the center displacement ø6 0.005 le (0.010) 5 15° G 20° 20Applications Features 1. Micro-lens array 1. World’s smallest ball endmill (R30 m) 2. Submillimeter lens with 2. World’s highest contour accuracy (50nm) curve free surface 3. Three dimensional precision can be attained 3. Molding for LCD display due to superior cutting edge optical waveguide 4. Microscopic machine part cutting Flat type 0.010 Applications 0.005 1. Screen sheet molding 0 2. Micro lens molding -0.005 3. Optical element molding Features -0.030 -0.020 -0.010 -0.010 0 0.010 0.020 0.030 X 1. Can machine both parabolic and elliptic surfaces of 1 m max. using same tool -0.015 Cutting edge 2. Shape integrity of parabolic and curved surfaces Inspection sheet guaranteed 54
  • 56. Cutting Ultra Precision Nano/Microforming Tools “UPC,” the series of ultra precision cutting tools developed by A.L.M.T. Corp. features an extremely sharp tool edge with a controlled waviness of 50 nm or less in high-precision aspheric and free-curve cutting. The edge preparation of the tool is nanometer accurate relative to the material characteristics that enable high-precision mirror surface finishing. Precision machined V groove from the free surface aspherical plane. Can also control the cutting edge radius. UPC-R shows extraordinary success in ultra precision spherical and aspherical cutting applications. Applications 1. CD • DVD pickup lenses molding 2. Molding for camera optical lenses 3. Spherical and aspherical reflecing mirrors for laser and x-ray equipment 4. Spherical and aspherical lenses 5. Other precision parts machined with CNC 2-axis lathe Features 1. A tool edge contour of 0.05µm (50nm) is achieved Enlarged view of over a wide working angle of 90º. 50.8 the tool nose 2. The cutting edge is precisely finished with minimal 40º waviness. The use of SEM at 2000x magnification for inspection eliminates chipping on the finished tool 6.35 edge surface. 3. A record of the tool edge contour obtained by our 0.5 newly developed measuring system (resolution of T 5nm) is attached to each tool to guarantee the Corner radius 5µm º quality. ■ Tool Nose Shape ■ Dimensions Limit Precision Contour Corner Tool Edge Tool Clearance Face Type Angle θ≤90° θ≤120° θ≤15° Radius R θ Width W Angle α Angle β Ultraprecision 0.05 m 0.15 m 0.20 m UPC-RT SS 0.005~ 15° 0°~20° -30°~10° Precision 0.5 m 1.0 m 2.0 m 3mm S Ultraprecision 0.05 m 0.15 m 0.20 m UPC-RR SS Precision 0.10~ 200mm 0.5~5.0 0°~20° -30°~10° 0.5 m 1.0 m 2.0 m S55
  • 57. UPC UPC-F excels in high-efficiency and ultra-precision surface and cylindrical cutting applications. Applications 1. Laser reflecting mirrors 2. Polygon mirrors 3. Copier sensitive drums 4. Ultra-fine flat or cylindrical surfaces Features 1. The time required for break-in operation for initial usage is eliminated or greatly reduced. 2. The edge preparation of the cutting tool is based on the 100 m material and the cutting conditions to provide a uniform and high quality surface finish. ■ Tool Nose Shape UPC-FC W ■ Shape Dimensions Tool Edge Tool Width Clearance Face Horizontal Corner Type Angle θ W Angle α Angle β Face Angle Y Radius R UPC-FC 45°~80° 1.0~4.0 0°~5° -5°~0° 0°~15° UPC-T is the optimal tool for fine grooving applications such as Fresnel lens. Applications 1. Molds of LCD display optical waveguide 2. Fresnel lens molding 3. Other fine grooving applications Features 1. The cutting edge is uniform and extremely sharp, without c chipping or undulation 2. The shape of the cutting edge 10 m is guaranteed to submicron Molds of LCD display optical waveguide■ Tool Nose Shape tolerances UPC-T ■ Shape Dimensions Tool Edge Leading Straightness Clearance Face Type Edge Width W Angle θ Angle α Angle β Ultraprecision min0.2 m 0.05 m SS UPC-T Precision min20° 0°~15° -5°~10° min2 m 0.1 m S 56
  • 58. Cutting Mono-crystal New Monocrystal Diamond Cutting Tools New D 1) verage tool life is 1.5~2 times that of conventional A mono-crystal diamond cutting tools with much less variation in individual tool life. 2) he combination of a proprietary insert and T holder design (design patent JAPAN) makes the tool setting as simple and precise as disposable inserts. 3) tandard designs for the inserts are for straight S cutting and for profile cutting. The tolerance of the inserts for profile cutting is with 5µm. New D mono-crystal diamond cutting tools 4) igh quality surface finishing is possible even H feature precision designed crystal orientation with continuous use because there is no fusion or acquired through x-ray analysis and are accumulation of chips on the rake face. strongly bonded on a carbide shank using a 5) The diamond is brazed strongly in place. newly developed method. 6) Outstanding durability even for interrupted cutting. Proprietary precision processing technology 7) nlike conventional mechanical clamp types, U used in their manufacture gives New D chips flow smoothly off the rake face for higher cutting tools a higher quality edge. precision. ■ Features  Data 1 Comparison of Tool Life and Stability for Interrupted Cutting (Data1.2) (Distance cut to flank wear width = 30µm) Cutting Speed: 565m/min Feed Rate: 0.2mm/rev Km D.O.C. : 0.12mm Cutting Fluid: alcohol-oil mist 8 Workpiece Material: High Si-Al alloy (Si:18%) 7 Cutting Distance 6 5 Data 2 Comparison of Tool Life 4 in Interrupted Cutting 3 m 2 100 C,D: Conventional monocrystal 1 New D tools Conventional tools diamond tools 90 D 80 C Data 3 Range of Recommended Cutting Conditions Flank Wear Width 70 mm/rev 60 0.2 Precision cutting range 50 A,B: New D tools Feed Rate 40 B 30 Mirror-finish cutting range A 0.1 20 10 1 2 3 4 5 6 7 8 Km 1.8 5.3 8.8 12.4 min Cutting Distance Time 0.05 0.15 mm ■ Process Example Cut 1) Profiling 2) Straight cut57
  • 59. New D■ Insert Types Types R I.C. Relief I.H. Thickness Insert Specifications øA øB h Holder Long Life Type Precision Type (mm) (mm) (mm) NWD-CL302 NWD-CP302 R0.2 NWD-CL305 NWD-CP305 R0.5 NWD-CL308 NWD-CP308 R0.8 NDH-R1 R NWD-CL310 - R1.0 -L1 55° NWD-CL316 - R1.6 4.4 +0.2 -N1 9.525 4-0 NWD-CL320 - R2.0 NDH-QR1 A NWD-PL302 NWD-PP302 R0.2 -QL1 h NWD-PL305 NWD-PP305 R0.5 NWD-PL308 NWD-PP308 R0.8 B NWD-PL202 NWD-PP202 R0.2 NDH-RO NWD-PL205 NWD-PP205 R0.5 6.35 2.8 +0.2 -LO 3-0 NWD-PL208 NWD-PP208 R0.8 -NO for aluminum wheels NDH-R20V NWD-CL416 NWD-CL416-AW R1.6 -L20V +0.2 35° 9.525 4.4 R NWD-CL420 NWD-CL420-AW R2.0 5.5-0 -R25V NWD-CL425 NWD-CL425-AW -L25V A R2.5 Precision type/cutting edge contour precision 5 m■ Holder Types Types Size (mm) Holder Specifications Insert Right Hand Left Hand W L S h L NDH-R06 NDH-L06 6 50 6.5 6 NWD-PP2 30° NDH-R08 NDH-L08 8 60 8.5 8 -PL2 NDH-R10 NDH-L10 W 10 80 10 10 S NDH-R12 NDH-L12 NWD-CL3 12 100 12 12 ° 95 NDH-R16 NDH-L16 -PL3 h 16 125 16 16 NDH-QR10 NDH-QL10 -CP3 L 10 80 13 10 17° 30° -PP3 NDH-QR12 NDH-QL12 12 100 15 12 NDH-QR16 NDH-QL16 16 125 19 16 W S 30° 7° 10 L NDH-R20V NDH-L20V 20 150 25 20 NWD-CL416 45° NDH-R25V NDH-L25V 25 150 32 25 -CL420 W -CL425 S 0° 10 L Free 62 °3 NDH-N06 6 50 - 6 NWD-PP2 0° NDH-N08 8 60 - 8 -PL2 NDH-N10 10 80 - 10 NWD-CL3 W -PL3 NDH-N12 12 100 - 12 30° -CP3 ° - 62 NDH-N16 16 125 16 -PP3 Please inquire for specifications except the above in the case of an order ■ Use Automotive parts (pistons, aluminum wheels, compressors, commutators, etc.) Plastic lens, resin molded parts HDD parts Aluminum die castings, other non-ferrous material 58
  • 60. Cutting e- Mono-crystal New D EDGE To meet customers’ demands for low cost and green operation, we introduce the New D e-EDGE for multi-purpose mono-crystal cutting tool for aluminum. Features 1) Low cost/high performance 2) Special holder for HDD aluminum die cast part and in stock 3) Special inserts for existing holders 4) Sharp cutting and very good cutting heat diffusibility Mono-crystal diamond cutting tool provides high performance at a low cost Application Electro equipment    HDD parts (hub, bracket) copy parts (drum, sleeve, plastic) Automobile component ■ Cost Comparison    Motor parts, transmission parts, air compressor, and Material: HDD part (A383) other high Si content aluminum parts Machine: CNC lathe Non-ferrous material e Tool: -EDGE / PCD cutting tool    Any PCD application      Rake: 0° Clearance: 7° * Please use the new Di-Byte mirror finish Condition: Vt: 480m/min      F: 0.04mm/rev      Stock Removal: 0.05mm Criteria: Burr Roughness: 0.8Ra Tool Life Cost Per Part (New) CPP (after 20,000 cuts) 20,000 pieces 6.4 1.0 20,000 6.0 1.0 5.0 # of Parts Price Index Cost Index 4.0 10,000 3.0 0.5 0.4 4,000 pieces 2.0 1.9 1.0 1.0 0 0 e-EDGE PCD e-EDGE PCD NewD e-EDGE PCD59
  • 61. e-EdgeHigh perfomance for dry cutting of aluminum die-cast alloy Insert Holder (Standard) Boring (Min. ø5.5mm) Size mm) Type R ( ° ■Example NWD-CE 101 0.1 7 80° R Cutting Force NWD-CE 102 0.2 7 Cutting (back component) [N] 5 NWD-PE 101 0.1 11 0 1.2+0.1 PCD (dry) NWD-PE 102 0.2 11 4 ø2.3 3 OD Turning/Copying to use with New D holder 2 PCD (wet) Size mm) ( 1 e- New D EDGE (dry) Type R ° 0 NWD-CE302 0.2 7 0 5 10 15 20 55° R NWD-CE304 0.4 7 Distance [km] NWD-CE308 0.8 7 NWD-CE312 1.2 7 Material: A383 3.38+0.2 0      ø105mm×280mm; interrupted NWD-PE302 0.2 11 Machine: CNC lathe ø4.4 NWD-PE304 0.4 11 Tool:   New D e -EDGE /PCD cutting tool NWD-PE308 0.8 11      Rake: 0° Clearance: 7° Conditions: Vt: 565m/min NWD-PE312 1.2 11       F: 0.1mm/rev      Stock removal: 0.2mm/dia. HDD/Aluminum Die-cast Part Coolant: -EDGE : Dry e New D      PCD: water emulsion Size(mm) Type R ゜ 40° R NWD-CEHD 01 0.1 7 NWD-CEHD 02 0.2 7 Results 3.7+0.2 e- 0 NWD-PEHD 01 0.1 11 New D EDGE E-Edge has lower cutting force NWD-PEHD 02 0.2 11 than PCD and maintains good cutting ø3 condition. Boring Holder (Min. ø5.5mm dia.) Size (mm) Type L D H W L E W øD BR/L08 Left 8 7 15  80 2.8 BR/R08 Right E BR/L10 Left 10 9 25 100 2.8 BR/R10 Right H HDD/Aluminum Die-cast Holder β° Size mm) ( Type H L E α゜ β゜ 10 +0.2 α° HDL10 10 80 2.5 15 35 Left E −0 L +0.2 HDR10 10 −0 80 2.5 15 35 Right H 60
  • 62. Reamer Endmill Cutting PCD Reamer Endmill High machining accuracy combined with mass-production at low cost is required for the processing of aluminum alloys for auto parts. Our PCD (Poly Crystalline Diamond) cutting tools achieve long tool life and high machining accuracy by constructing sharp High machining accuracy combined with mass-production at low cost is required for the processing of aluminum alloys for auto parts. Our PCD (Poly Crystalline Diamond) cutting tools achieve long tool life and high machining accuracy by constructing sharp cutting edges which use grinding technology applied to PCD. The resulting special feature is that tool hardness is effectively more than 10 times that of carbide tools. Longer life of PCD cutting tools improves productivity, reduces the frequency of tool replacement and machining cost. In addition, machining accuracy and discharge of cutting chips have been improved by cutting edge grinding technology and strengthening the breaker function. A.L.M.T. will respond to all requests from diversified automobile parts manufacturers as a pioneer manufacturer of diamond tools. Our PCD reamers make efficient and high-speed cutting possible Advantages gained by upgrading from a carbide reamer to a PCD reamer Improvement in tool life Improvement in machining accuracy Reduction in machine time Reduction in frequency of tool replacement «Reduction of Tooling Cost and Improvements in Productivity» Tool Life Work Material Carbide PCD ADC12 (Contains 12% Si) 1 10~20 A390 (Contains 18% Si) 1 20~ Cutting Machine Time (Test) Item Carbide PCD # of Rotations N(min-1) 2000 6000 Cutting Speed V(m/min) 125 380 Feed Rate f(mm/min) 400 1800 Machining Time 3 : 1 Tool Size ø20×4NT(Machining Depth 20mm) Number of Tool Replacement (Test) Item Carbide PCD # of Tool Replacements 10 times once Cylinder head Cylinder block Purposes Non-ferrous Metal Machined Components (Aluminum Alloy) Transmission/steering components Compressor components 1. Multi-stage machining can be done on one pass by using an integrated profiled step tool. Features 2. Long tool life with sharp cutting edge made by adopted grinding technology that provides excellent sharpness and wear resistance compared to cemented carbide tools. 3. Excellent machining surfaces can be obtained by rapid feed even with cutting speeds at 500 m/min. 4. Stable cutting and sufficient performance when using emulsion type water-soluble coolant. 5. New mechanism that prevents various common machining problems. Vibration, chattering → Assurance of dynamic balance Ex. of problems Built-up edge → Surface finishing to prevent built-up edge Clogging of tools with cutting chips → Chipbreaker process 61
  • 63. Comparison of carbide reamer to PCD reamer The position of diamonds In the field of cutting tools, diamonds with excellent material features are in the limelight as the material that is expected to be applied Harder for fine shape machining as well as various Diamond requests and issues in high grade and high cBN efficient machining. Ceramics Coated cemented carbide Cermet Carbide High speed steel Hardeness Intensity Toughness ・ Higher Material Features of PCD The features of PCD (Poly Crystalline Diamond) in poly crystalline cutting tool materials are as follows: 1) Hardness is high 2) Thermal conductivity is high 3) Coefficient of thermal expansion is small. It has excellent thermal conductivity and hardness, which is required for cutting tools, compared to other tool materials. Knoop Hardness (GPa) Thermal Conductivity (W/m · C°) 50 560 (W/m · C°) (Gpa) 23 17 16 200 110 4 Aluminum Oxide Carbide Carbide Aluminum Oxide cBN cBN PCD PCD Comparison of Cutting Performance Between PCD (Poly Crystalline Diamond) and Carbide Tools A390-T36 and ADC-12 that are widely used as a main material for automotive Longer life than carbide components had many problems such as grade of processing surface and running cost of machining with carbide cutting tools. Using PCD has solved various by a ratio of 10 to 20 times problems, especially machining ADC-12 which is difficult to cut due to its longer tool life and stable machining accuracy compared to carbide. A390-T6 Cutting distance and flank face wear width ADC12 Cutting distance and flank face wear width Cutting distance (Km) 0.6 1.0 1.5 2.0 3.0 4.0 5.0 Cutting distance (Km) 0.6 1.0 2.0 6.0 10.0 20.0 30.0 PCD flank face wear width ( m) 35 50 55 60 70 80 PCD flank face wear width ( m) 10 20 22 30 40 70 100 Carbide flank face wear width ( m) 600 1000 1500 Immeasurable Carbide flank face wear width ( m) 30 35 40 55 90 200 ー 1600 Flank Face Wear Width ( m) Flank Face Wear Width ( m) 200 1400 Short tool life due to heavy wear and machining face grade NG 1200 100 1000 Stopped due to poor cutting performance 90 80 800 Carbide Carbide 70 PCD 600 PCD 60 50 400 40 200 30 20 10 0 0.6 1 1.5 2 3 4 5 0.6 1 2 4 6 8 10 20 30 Cutting Distance (km) Cutting Distance (km) 62
  • 64. Reamer Endmill Cutting Data.1 Amazing accuracy Generated from segmented cutting chips Edge honing specification cutting edge Solving problems A. Length of cutting chips 1) Edge honing specifications Bend the flow of cutting chips moderately to shorten the cutting chip length. 2) Chipreaker specifications As a means to eliminate loss of productivity, Curl the cutting chips by the wall surface the chipbreaker has been enhanced. of the chipbreaker to forcibly shorten the length of cutting chips. B. Width of cutting chips 3) Nick Specifications Shorten the width of cutting chips by a Split cutting chips dent prepared on the cutting edge. Cutting resistance and contour accuracy have been improved by grinding technology Chips curl thickly and split Conventional machining Special grinding machining Old New ブレーカー無し ブレーカー有り Without chipbreaker With chipbreaker High machining accuracy due to non-opaque granular chips Data.2 Superior design and quality Capable of both high efficiency cutting and high machining accuracy The concentricity and cylindricality of cutting edges have greatly improved due to high shank rigidity (carbide) and grinding technology on the cutting edge. The machining efficiency per cutting edge has improved by cutting down the machine time. Machining Conditions Workpiece Cylinder head, valve seat, guide hole Material Aluminum alloy casting AC4B Machines Horizontal machining center Valve Seat Hole Tool Size ø11-ø36-L150 # of Rotations (min-1) 3500 Cutting Speed (m/min) 395 Feed Rate (mm/rev) 0.3 D.O.C.(mm/dia.) 0.5 Valve Guide Hole Coolant Emulsion type water-soluble Deformation volume by CAE analysis Shank Material: Steel Shank Material: Cemented Carbide Diagram of work material Cross section of machining tool 4 Teeth Differences of Performance Between Shank Materials (carbide) Machining Results 1 Tooth 4 Teeth (steel) 4 Teeth (carbide) 4 Teeth (steel) Machining time (s) 52 26 13 Circularity (mm) 0.01 0.05 0.03 1 Tooth Coaxiality (mm) 0.01 0.07 0.05 0 10 20 30 40 50 63 Machining Time (s)
  • 65. Machining Application Valve seat and guide hole HLA (Hydraulic Lash) adjuster hole finishing Intake exhaust valve guide hole finishing Valve seat and guide hole finishing The issues such as concentricity and cylindricality are solved by high shank rigidity and high cutting edge accuracy. ■ Valve seat and guide hole finishing specifications Machine: Horizontal machining center # of Rotations (min-1) 6,000 Feed Rate (mm/rev) 0.48 Machining Conditions Feed Speed (mm/min) 2,880 D.O.C. (mm/dia) 0.6 Coolant Emulsion type water-soluble Hydraulic lash adjuster hole finishing The issues such as chip removal and cylindricality are solved by the design that responded to thin-walled blind hole machining portions. ■ Hydraulic lash adjuster hole finishing specifications Machine: Horizontal machining center # of Rotations (min-1) 5,000 Feed Rate (mm/rev) 0.34 Machining Conditions Feed Speed (mm/min) 1,540 D.O.C. (mm/dia) 0.5 Coolant Emulsion type water-soluble Intake exhaust valve guide hole finishing Concentricity and cylindricality of the cutting edge are controlled by its high accuracy and the self-guide effect is enhanced in order to respond to long overhang and bending. Moreover, the discharge amount of chips by the guide hole shape and coolant design. As a result, it can machine 10 times the number of holes compared to cemented carbide to improve productivity. ■ Intake exhaust valve guide hole finishing specifications Machine: Horizontal machining center # of Rotations (min-1) 3,250 Feed Rate (mm/rev) 0.1 Machining Conditions Feed Speed (mm/min) 325 D.O.C. (mm/dia) 0.1 Coolant Emulsion type water-soluble ■ Machining Results Tool Life Ratio Ratio Cutting Tool (# machined holes) of prices of costs Coaxiality Inner diameter change volume Carbide 1,200 1 1 — — Our PCD tool 12,000 3 0.8 10 m 3 m/10,000 hole 64
  • 66. Cutting Reamer PCD REAMER Application of PCD reamer machining Reamer machining of automobile hydraulic regular valves 56 Item Carbide Reamer PCD Reamer ø10 Cutting Speed (m/min) 120 120 Feed Speed (mm/rev) 0.2 0.2 D.O.C. (mm/dia) 0.4 0.4 Coolant oil-based water-soluble Surface Roughness ( mRz) 8 3 Circularity 10 5 Running Cost 1 0.5 Workpiece 180 ■ Shape ø16 ø10 Cutting Edge Cutting Edge Dia. øD Dia. øD Other Specifications ø3~ø4 1 tooth Blade dia. tolerance - Standard specifications: øD±0.0025mm ø4~ø6 3 teeth High-accurate specifications: øD±0.0015mm (ø5; ø25) (80) ø6~ø8 4 teeth Along the length - Max. length: 450mm (Standard L/D=3~5) ø8 6 teeth Our Products PCD reamer (single-step reamer) Body Materials 1) Solid carbide 2) Comb. of carbide steel 3) Hardened steel Applications HDD, CD-ROM, rocker arms, etc. ødh7 øD Carbide guide area L PCD reamer (with chamfering tip) Body Materials 1) Solid carbide 2) Comb. of carbide steel 3) Hardened steel Applications Compressor body, ABS actuator, power steering body, etc. ødh7 øD L PCD reamer (PCD profiled step reamer) Body Materials 1) Solid carbide 2) Comb. of carbide steel 3) Hardened steel Applications Oil pumps, steering, AT hydraulic control body, etc. ødh7 øD L PCD gun reamer (multiple step reamer) Body Materials 1) Comb. of carbide steel Applications AT hydraulic control body, etc. ødh7 øD L PCD reamer (with breakers) Body Materials 1) Comb. of carbide steel Applications ABS body, oil pumps, AT hydraulic control body, etc. ødh7 øD L65
  • 67. Endmill PCD ENDMILL Application of PCD ballnose endmill Ballnose endmill (straight type) Machining of spherical surface on compressor parts for automobile air conditioner ■ Application of Machining Roughness 1.6 mRz or less Results Circularity 5.0 m Workpiece ADC12 [contains Si 11.5%] ■ Possible Manufacturing Range # of rotations N=1200 [rpm] Conditions Feed f=0.005 [mm/rev] final Length of 8mm or less ø15.9×100L cutting edge ) (at rake angle 0°: can machine up to 25mm) ( Tool Spherical tolerance ±0.01mm Rake Angle θ 5° less or Radius tolerance ±0.01mm (Axial rake) (at 10°: cutting edge length 4mm or less) ■ Shape ■ Contour Level Data 2 m Cutting Edge Cutting Edge Dia. øD Dia. øD Other Specifications ø3~ø4 1 tooth Blade dia. tolerance - Standard specifications: øD±0.1mm ø4~ø6 or less 3 teeth High-accurate specifications: øD±0.01mm (ø5 or more ø25 or less) 100° ø6~ø8 or less 4 teeth Along the length - Max. length: 450mm (Standard L/D=3~5) (area of ø8 or more 6 teeth measurement)Our Products PCD endmill (ballnose endmill) Body Materials 1) Solid carbide 2) Hardened steel Applications Compressor parts, etc. ødh7 øD R PCD endmill (T-slot) Body Materials 1) Solid carbide 2) Hardened steel Applications T-groove slotting A tooth B tooth ødh7 øD B tooth L A tooth PCD endmill (for deburring casting parts) Body Materials 1) Solid carbide 2) Hardened steel Applications HDD, cylinder block ødh7 øD rC Ro L θ PCD spot facing cutter Body Materials 1) Solid carbide 2) Hardened steel Applications Various spot facing machining ødh7 øD L 66
  • 68. Cutting PCD Circular Saw Our PCD Circular Saw is capable of high accuracy machining while providing noise reduction with long lasting quality as a result of analyzing individual factors such as superior tool performance and improving an operating environment and terra-ecology. Features Newly developed VC mark reduces 15% of vibration Cost competitive with new PCD and blade shape Application Aluminum casting gate cutting Grooving for circuit board electric parts PCD Circular Saw 3i-Force ■ Comparison of Tool Life 10 i-Force Intelligent Force 8 6 Index Noise Cost 4 Accuracy Reduction Effective 2 3 i-Force provides high performance and cost reduction due to matching the blade shape and the newly developed VC mark 0 Carbide Conventional New --our own innovative design. PCD PCD 1. Best combination of cutting edge shape Sharply-ground new V flat blade is exceptional with low-power cutting and cost performance Specifications: ø250 - 6T - 8NT Speed ………………2,365rpm New VF Flat Blade D.O.C. ………… 30mm/pass Chip segmentation and cutting force reduction Feed/tooth…19 m Tested with 0.2mm pre-wear  ■ Comparison by Blade Shape B on Aluminum Gate Cutting Spindle Current 1.2 Value A) ( 1.0 A 1.0 0.78 0.8 Index 0.6 0.4 0.2 0 A. Flat blade B. V blade Staggered VF A.L.M.T. A.L.M.T. (old VF) (new VF)67
  • 69. Circular SawDATA 2. Damping effect by newly developed VC mark New VC mark was developed by using 3-dimensional CAE analysis and a test model trial. New VC mark suppresses cutting vibration max. 15% and provides a comfortable operationg environment. 105 101 100 Noise Value (dB) Z 95 Y 92 X 90 85 85 Waved form chart shows damping effect by type. Newly 80 developed VC mark provides high accracy cutting while reducing 75 chipping of cutting edge. No Mark Old New VC Mark VC Mark ■ Comparison of Dampened Wave No Old New Mark VC Mark VC Mark → Amplitude → Time DATA 3. 2 effects by unique Prevent deformation and tip elimination by cutting heat slit shape Thinner cutters are required for chips and power reduction according to Green Procurement on ISO14000s. Special attention to detail has resulted in the succesful development of the slit, which reduces stress and cuts heat. 1) Release internal stains and reduce side run-out 2) Dissipate cutting heat and protect tip brazing Max. principle stress (with slit) Max. principle stress (without slit) 68
  • 70. Cutting Diamond Wire Saw Diamond Wire Saw PWS ■ Features of PWS (PWS-R · E) Pat. #3078020 Precision Wire Saw • High-precision, high efficiency (cutting speed: 2 to 10 times the loose grain) • Improve the work environment (a water-soluble machining fluid can be used) • Significantly improved recycling (separation of the chips can be recovered) • Application can be selected according to the needs specification Environmentally friendly slicing Fixed Abrasive Diamond Wire Saw technology continues to evolve... ■ Applications • Glass, ceramics, quartz and brittle materials such as sapphire • Magnetic material such as neodymium and ferrite magnets • Semiconductors and silicon for solar cells • More difficult to cut materials SiC, various substrates ■ Standard Specification For Fixed Abrasive Diamond Wire Saw Formula Average Particle Production Type Diameter Dia. Length PWS-R ø0.245±0.01 40−60 m ~100km PWS-E ø0.255±0.01 30−40 m ~50km *For long products, and other specifications, please contact us. -R Type -E Type (Resin Type) (Electrodeposition Type) -R Type -E Type surface surface ■ PWS-R Features ■ PWS-E Features • Ideal for maching a variety of materials • To achieve high efficiency machining • Capable of high quality finishing with abrasive high retention69
  • 71. PWS Outline of Multi-wire Saw Workpiece Nozzle Nozzle Main Roller Main Roller■ Case Processing Specifications: PWS PWS-R PWS-R PWS-E Evaluation System Multi-wire saw Multi-wire saw Multi-wire saw Work Material Neodymium magnets Plate Glass Sapphire Materials W(50×4columns)×H(25×4high)×L(50×2columns)mm ø50mm×L200mm ø50mm×L200mm Dimension Wire Speed max800m/min max400m/min max400m/min Work Feed Speed 0.6mm/min Ave0.1mm/min Ave0.3mm/min Cutting Wire Running Direction Round-trip running Round-trip running Round-trip running Condition Wire Tension 30N 35N 35N Slurry Water-insoluble slurry Water-soluble slurry Water-soluble slurry Surface Roughness (Ra) on and less than 1.5 m on and less than 0.4 m on and less than 0.5 m Waviness (WCM) on and less than 20 m on and less than 30 m on and less than 30 m Cutting Total Thickness Variation TTV) ( on and less than 10 m on and less than 10 m on and less than 10 m Results Average Thickness 0.74mm 0.6mm 0.6mm Kerf-loss 0.26mm 0.26mm 0.26mm Dia. of Core Wire 40−60 m 30−40 m PWS Specification Ave. 0.25mm Ave. 0.255mm Outer Diameter * Total length of cutting direction was measured.HighCut-through ResistanceLow Workpiece: glass, alumina, sapphire Slurry A Slurry B Slurry CCutting resistance varies depending on the working fluid. Please contact us for assistance in selecting the optimal working fluid. 70
  • 72. Other Products For Carbide Tool GrindingCPG ODIUP CPG Series Compact Tool Grinders ・ ■ Features 1) Incomparable rigidity Precise angler bearing for grinding spindle High Operativity and High Output and pivot Constant feed and handwheel operated oscillating width control. 2) Excellent grind accuracy Super rigid grinding spindle for sharp cutting X20 projector for centering and profiling. edge grinding ■ Specifications 3) Highly efficient operation ø150mm projector Quick cutting edge angle and relief angle with Constant feed unit oscillating location adjustment of wheel with workpiece sight. Leaning mechanics with Coolant unit centering grinding point and highly precise Holder (QC-21) projector for high efficiency operating environment. Basic grinder for low volume production X20 projector for centering and profiling ■ Options Special power-up units for CPG Series Depth Feed Digital Meter Angle Digital Meter Coolant Tank CPG-310 Angle measuring encoder Paper filler type Linear scale (min. (min. 1 min.) 1µm) CPG-200 Ball screw and length measuring encoder ■ Accessories Special jigs for CPG series Holders Jig for cylindrical grinding Brake trueing unit BT-2 3-D vise On machine dressing CT-1 Jig for radius grinding Jig for negative land (CPG-310) 71
  • 73. Trueing Unit Brake Dresser Features Instructions The brake dresser consists of a grinding wheel, bearing, and brake controller. The grinding wheel drags with a rotating diamond grinding wheel. At high speeds, the brake shoe causes friction by centrifugal force, and peripheral speed difference between grinding wheels reduction of drag speed. This press force and peripheral speed difference removes run-out on the diamond layer. To remove the hard wear layer or make the layer straight, traverse table feed and intermittant wheel feed are required. Dimensions Example Brake Dresser 10° 15° 108 88 traverse direction ø9 46 Diamond wheel 100 165 ODIAP Grinding Fluid Feature Water soluble grinding fluid specialized for fixed abrasive operation ■ Application PWS DPG 72
  • 74. Other ProductsPins Files Diamond/cBN Standard Grinding Pins W11 Grinding Pin W12 Grinding Pin L L T C0.5 1 C0.5 T øD øY +0 -0.02 øD ød øY +0 -0.02 CD D T L Grit # CD D T d L Y Grit # W11003 SD 0.3 2 5 35 #800 W12035 SD 3.5 5 - 60 3 #120 W11004 SD 0.4 2 5 35 #400 W12040 SD 4.0 5 - 60 3 #120 W11005 SD 0.5 2 8 35 #400 W12045 SD 4.5 5 - 60 3 #120 W11006 SD 0.6 3 8 40 #200 W12050 SD 5.0 5 2 70 3 #120 W11007 SD 0.7 3 8 40 #200 W12060 SD 6.0 8 3 70 3 #120 W11008 SD 0.8 3 10 40 #200 W12070 SD 7.0 8 4 70 6 #120 W11009 SD 0.9 3 10 40 #200 W12080 SD 8.0 8 5 70 6 #120 SD 1.0 3 10 40 #200 W12090 SD 9.0 8 6 70 6 #120 W11010 LD 1.0 3 15 40 #200 W12100 SD 10.0 10 7 100 6 #120 SD 1.2 5 10 45 #200 W12120 SD 12.0 10 9 100 10 #120 W11012 LD 1.2 5 15 45 #200 W12150 SD 15.0 10 12 100 10 #120 SD 1.3 5 10 45 #200 W11013 LD 1.3 5 15 45 #200 SD 1.5 5 10 45 #200 W11015 LD 1.5 5 17 45 #200 SD 1.7 5 13 45 #200 W11017 LD 1.7 5 20 45 #200 SD 2.0 5 13 45 #200 W11020 LD 2.0 5 20 45 #200 SD 2.3 5 13 45 #200 W11023 LD 2.3 5 20 45 #200 SD 2.5 5 13 45 #120 W11025 LD 2.5 5 20 45 #120 SD 3.0 5 15 50 #120 W11030 LD 3.0 5 22 50 #120 * SD 6.0 5 20 65 #120 W11060 LD 6.0 5 27 65 #120 (Y=ø3 but *Y=ø6) 73
  • 75. Handy Diamond File - Standard N Handy File for Precision F Handy File for Iron L L d d 5 9 L d 1 2 3 4 Three 6 7 8 Balance X Y Z Application Type CD Grit # Flat Half Round Round Square Square Taper Oval Swaged Edge Knife Crossing Clam G 10 Piece 7310 #140 140 50 ø3 value set 5 pcs set 7320 #200 200 70 ø4 (N) 8 pcs set 7330 #200 180 70 ø3.4 10 pcs set 7340 #140 140 50 ø3 12 pcs set 7350 #120 140 40 2.2 5 pcs set 7360 #120 215 80 Square 8 pcs set 7370 #120 200 70 Square (F) 10 pcs set 7380 #120 185 50 Square 12 pcs set 7390 #120 170 40 Square* Please contact us about stock.* Service Set 10 pcs, 10 pcs for precision (No.7340) is a set of five triangular flat half-circle round the corner. 74
  • 76. CTCInformation The application field of diamond and cBN tools is very wide and diversified, and the demand on the tools is also severe and wide-ranged in accuracy, efficiency, tool life, and environmental concerns. In order to meet demands, A.L.M.T. Corp. established the Customer Technical Center as a solution center to assist and support customers. The CTC is composed of three sections: 1) platform, 2) process evaluation, including measurement and inspection, and 3) presentation and meeting room. Platform Products and technologies developed from basic technologies Presentation Meeting Room Processing Exploring new technologies Realizing customer satisfaction CTC supports our customers’ engineering development Shape a theme through verification and discovery Customer From Inquiry to Report The issues at hand are: environment, increase in productivity, cost reduction, number of requests that require quality improvement, and discussion and Order trial Technical technical issues; problem solving is a measure of success. evaluation consultation Report trial result Quote Tool techniques Lay out technologies in four themes for info trial operatrion Platform The products and technologies developed by A.L.M.T. Corp. are illustrated (left). There are 4 sectors: Cutting, Grinding, Polishing, and Forming. New and flexible solutions to diversified requests, plus information to make conclusions regarding future related issues. Technical database though production and measurement Operation and Evaluation Leading-edge processing can only be achieved with up-to-date machines. In this sector, the leading machines installed are classified into three groups: 1) high efficiency processing, 2) wire slicing with bonded wire saw, and 3) precision processing. In each grouping, tools and work to be processed are tried and evaluated on the spot with installed measurement equipment. 75
  • 77. Processing Evaluation Division Corresponds to the processing facility at the request of various evaluations HighEfficiency Grinding Center High Precision Precision Rotary Surface Grinder ■ Equipment Overview ■ Equipment Overview Based on the machining center manufactured Built-in motor type air spindle is precisie with water-cooled by Hitachi Seiki VK55; was developed by adding heat to enable smooth rotation with little vibration search capabilities to machining is the best displacement. Applied to the evaluation process, such machine for grinding center. as a silicon wafer with fine wheel. ■ Typical Applications Evaluation ■ Typical Application Evaluation Ceramics, carbide, hardened steel grinding,   ・Silicon wafer processing such as fine wheel test. complex action processing HighEfficiency Vertical High Speed Machining Center ■ Equipment Overview With axial core cooling, its unique lubrication under High Precision Precision Slicer race lubrication hollow ball screw cooling system ■ Equipment Overview and high-speed spindle, high rigidity 50m/min. in Ultra-precision air bearings with static pressure on the spindle, the body structure, high capacity due to high feed small and accurate feeding makes this a high precision slicer. rate of 0.6G has achieved a processing rate. ■ Typical Application Evaluation ■ Typical Application Evaluation Ceramics by slicing blade, stacked evaluation tests, CVD tool life evaluation tests in aluminum alloy such as slicing condenser machining New composite materials processing characterization using test tools PSL *CVD: Chemical Vapor Deposition (Diamond coated by chemical vapor synthesis) High Precision High Speed Slicer ■ Equipment Overview HighEfficiency Double-axis Surface Grinder - Opposite Equipped with a discharge trueing system, ideally on a (Vertical Type) machine Tsuru can swing. Evaluated by automatic ■ Equipment Overview alignment to speed. S wheel adopts an air spindle and To pass through the axis of the workpiece between low-vibration spindle thermal displacement. the two wheels facing up and down by immediate vertical surface grinding. Has a highly rigid spindle ■ Typical Application Evaluation held by the prismatic slide. Adapted to the evaluation process such as wafer thin blade. ■ Typical Applications Evaluation Ferrous sintered Processing of mechanical parts such as two-sided machining castings efficiency, dimensional surface Green accuracy evaluation test Machining DPG (Diamond Pellets and Grinding) ■ Equipment Overview Based on technology developed by lapping, diamond HighEfficiency NC High Speed Cylindrical Grinding Machine pellets rigidity that is required for fixed abrasive grinding. ■ Equipment Overview The process by wrapping loose grain, fixed abrasive Ultrafast NCs largest cylindrical wheel with peripheral greener can be evaluated when it is changed to speed up to 160m/sec. as a grinder. Plunge of processing. ferrous material at high peripheral speed, Kontari switching conduct the search, can be evaluated. ■ Typical Application Evaluation Ceramics, quartz, glass, in the conventional planar ■ Typical Application Evaluation processing of metallic materials to move to high-efficiency High peripheral speed and cylindrical grinding to grinding process by DPG from lap when processing TVG9 improve efficiency on iron-based materials processing efficiency, reach the surface roughness evaluation test work test For the purpose of reducing the high peripheral speed and the grinding wheel wear. PWS Multi-wire Sawing Machine Green Machining ■ Equipment Overview Fixed abrasive diamond wire saw (PWS) using a multi-wire. A machine for cutting only. Does not require a loose grain as well as DPG. ■ Typical Application Evaluation Sapphire, multi-processing efficiency in cutting, such as silicon, flat trial evaluation. Measure Analysis Division Profile, accuracy, and analysis using the latest equipment Flatness Measuring Equipment 3-D Surface Structure Analysis Flat Master 200XR Equipment ZYGO Scanning Electron Microscope EDX-SEM Spin Tester 76
  • 78. NetworkInformation Technical Reliable Network for A.L.M.T. Corp Based on the domestic production subsidiaries with high technologies, the sales network close to the local and overseas markets and the manufacturing affiliates overseas, A.L.M.T. Corp. serve society both at home and abroad with reliable products Domestic Affiliates (Diamond Tool) A.L.M.T. DIAMOND Corp. (Harima Plant) A.L.M.T. DIAMOND Corp. (Shizuoka Plant)   Ajawi Diamond Industrial Co., Ltd. Global Network (Diamond Tool) Sales Production, Sales North America Sumitomo Electric Carbide, Inc. 1001. Business Center Drive, Mt. Prospect, IL 60056-0545, U.S.A Tel: 1-847-635-0044 Fax 1-847-635-9335 : Sumitomo Electric Carbide, Inc. 14496 Sheldon Road, Suite 230, Plymouth, MI 48170, U.S.A. Tel: 1-734-451-0200 Fax 1-734-451-5338 : China Henan A.L.M.T. Whirlwind Diamond Wheel Co., Ltd. 200 Renmin Road, Changge City, Henan Province China 461500 TEL : +86-374-6108758 FAX : +86-374-6108859 Henan A.L.M.T. Whirlwind Diamond Wheel Co., Ltd. 200 Renmin Road, Changge City, Henan Province China 461500 TEL : +86-374-6108766 +86-374-6108768 FAX : +86-374-6108769 A.L.M.T. Diamond Dies SUZHOU) ( Co.,Ltd. Unit 25D, 25E Of Suchun Industrial Square, #428 Xinglong Street Suzhou Industrial Park, Jiangsu, P.R. China 215021 TEL : +86-512-62836195∼7 FAX : +86-512-62836176 Taiwan Chyi Meei Precision Industry Co.,Ltd. 7F, No.32, Lane513, Juikung RD., Neihu, Taipei, Taiwan (Far-East Hi-Tec. a Center) TEL : +886-2-26590955 FAX : +886-2-26572929 South East Asia A.L.M.T. Asia Pacific Pte. Ltd.   No.2 Boon Leat Terrace #03-02/03 Harbourside 2 Singapore 119844 TEL : +65-6271-9252 FAX : +65-6274-2915 A.L.M.T. Asia Pacific Pte. Ltd.   A-3-1 Mines Waterfront Business Park No.3, Jalan Tasik, The Mines Resort City, 43300 Seri Kembangan, Selangor Darul Ehsan Malaysia TEL : +60-3-8945-1090∼1 FAX : +60-3-8945-1092 A.L.M.T. (Thailand) Co.,Ltd.   90/2 Moo.9, Wellgrow Industrial Estate Bangna-Trad Road Km36, Bangwua, Bangpakong Chachoensao 24180 Thailand TEL : +66-38-522291∼4 FAX : +66-38-522290 A.L.M.T. (Thailand) Co.,Ltd.) 54 B.B.Building, Room1511,15th Floor, Sukhumvit 21 Road (Asoke), North Klongtoey, Wattana,Bangkok10110 Thailand 77 TEL:+66-2-2612231∼2 FAX:+66-2-2612230
  • 79. Head Office 1-11-11, Shiba, Minato-ku, Tokyo, 105-0014 TEL: +81-3-5418-1801 FAX: +81-3-5418-1810p. URL http://www.allied-material.co.jp/ Laboratories Development and Design Department 1-1-1, Koyakita, Itami City, Hyogo 664-0016 (within Itami Plant of Sumitomo Electric Industries, Ltd. Corporation) Materials Research Department 2, Iwase-Koshi-machi, Toyama City, Toyama 931-8543 TEL: +81-76-437-1951 FAX: +81-76-438-9033 Tools Research Department 1816-174, Kotaka-Kuroishi, Kato City, Hyogo 679-0221 TEL: +81-795-48-1778 FAX: +81-795-48-1779 Domestic Affiliates (Functional Material) Sales Departments A.L.M.T. TECH Inc. (Sakata Plant) Functional Materials Group   1-11-11, Shiba, Minato-ku, Tokyo, 105-0014 A.L.M.T. TECH Inc. (Toyama Plant) TEL: +81-3-5418-1805 FAX: +81-3-5418-1811   Diamond Tool Group A.L.M.T. TECH Inc. (Itami Plant) 1-11-11, Shiba, Minato-ku, Tokyo, 105-0014   TEL: +81-3-5418-1809 FAX: +81-3-5418-1811 A.L.M.T. TUNGSTEN Corp. (Toyama Plant) Global Network (Functional Material) Sales Production, Sales Europe Sumitomo Electric Hartmetall GmbH Siemensring 84, D-47877 Willich, Germany Tel: 49-2154-49920 Fax 49-2154-41072 : North America Sumitomo Electric U.S.A.,INC. 21221 S. Western Avenue, Suite 200 Torrance,California 90501, U.S.A. Tel: 1-310-782-0227 Fax 1-310-782-0211 : China Chengdu Liang Hong Molybdenum Co., Ltd. No.198 Nanjing Road, Chengdu Economic And Technological Development Zone, Longquanyi District, Chengdu, China TEL : +86-28-88432459 FAX : +86-28-88432456 78
  • 80. URL http://www.allied-material.co.jpSumitomo Headquarters - U.S. Detroit Branch 1001 Business Center Drive 14496 Sheldon Road #230 Mount Prospect, IL  60056-2181 Plymouth, MI 48170 P.O. Box 545, Mt. Prospect, IL 60056-0545 Phone: (800) 239-5177 Phone: (800) 950-5202 Phone: (734) 451-0200 Phone: (847) 635-0044 Fax: (734) 451-5338 Fax: (847) 635-7866 http://www.sumicarbide.comCincinnati Branch Huntsville Branch 4450 Carver Woods Drive 5650 Sanderson Street NW Cincinnati, OH 45242-5545 Suite J Phone: (800) 879-1887 Huntsville, AL 35805 Phone: (513) 891-4000 Phone: (256) 895-2845 Fax: (513) 794-2911 Fax: (256) 895-3150Torrance Branch 21241 South Western Avenue Suite 120 Torrance, CA 90501 Phone: (800) 950-5202 Fax: (310) 782-0211Sumitomo Hardmetal Mexico(SHMM) Av. Aguascalientes Sur 2625, Fracc. Jardines de las Fuentes Aguascalientes, AGS Mexico C.P. 20290 Phone: 011-52-449-993-2740 Fax: 011-52-449-993-2753 2011.08