Diamondxcbn Tools

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Diamondx cBN Tools Diamond xcBN Tools Nano technology and Eco-friendly tools from A.L.M.T. bring next generation of cutting, grinding, and polishing.

◆…interpretation ◇…product Grinding Tools P3~23

◆Wheel / General...... P 3 - 4 ◇VITMATE...... P15 ◆Bond Types...... P 5 - 6 ◇EG Wheel ...... P16 ◆Truing & Dressing ...... P 7 ◇Nanomate ...... P17 - 18 ◆Wheel Shape 1 ...... P 8 ◇MT Bond Wheel ...... P19 ◆Wheel Shape 2 ...... P 9 - 10 ◇MB SPARK...... P20 ◇Flute MAX ...... P11 ◇DPG Wheel...... P21 ◇Flute Master...... P12 ◇Super Sizing, CMP Conditioner ...... P22 ◇Hybrid Wheel ...... P13 ◇Electro-plated Internal Wheel ...... P23 ◇Flank Master ...... P14

Dresser P24~31

◆Types ...... P24 ◆Inspection (+Recommended Dressing Conditions) .... P28 ◆Production Range ...... P25 ◆Technical Information...... P29 ◆(Profile) Accuracy...... P26 ◇Dresser / Other ...... P30 - 31 ◆Options ...... P27

Cutting Tools P32~46

◆Diamond Types...... P32 ◇NewD, e-EDGE ...... P39 - 40 ◆UPC ...... P33 ◇Ultrasonic (vibration) assisted cutting system .... P41 ◇BL-UPC...... P34 ◆PCD Rotating Tool...... P42 - 45 ◇UPC Nano...... P35 - 36 ◇PCD Small saw...... P46 ◇UPC (-R, -F, -T)...... P37 - 38

Diamond Wire Saw P47~48

◆PWS...... P47 - 48

Other P49~50

◇CPG Series...... P49 - 50

Information P51~56

◆Customer Solution Center ...... P51 - 52 ◆Network / Other Catalogue ...... P55 - 56 ◆Safety Precautions...... P53 - 54

1 Index 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.

P11 P12 P13 P14 P15 P16 P17 Flute MAX Flute Master Hybrid Wheel Flank Master VITMATE EG Wheel Nanomate V-Heart

P17 - 18 P19 P20 P21 P22 P22 P23 Electro-plated Nanomate Premium MT Bond Wheel MB SPARK DPG Wheel Super Sizing CMP Conditioner Internal Wheel

P25 P30 Rotary Dresser P30 P31 P31 Rotary Dresser for Internal Grinder Crown Dresser Disk Dresser CVD Ace Dresser

P34 P35 P35 P36 P36 P37 P38 BL-UPC UPC-Nano groove UPC-Nano endmill UPC-Nano ballendmill UPC-Nano Profile UPC-R UPC-F

P38 P39-40 P41 Ultrasonic P42-45 P46 UPC-T NewD, e-EDGE Assisted Cutting Unit PCD Rotating Tool PCD Small Saw

P48 P48 PWS-R PWS-E

P49 P50 P50 P50 P50 CPG Tool Grinders RD Drive Unit Brake Dresser ODIUP TACUMINO Dress

2 Grinding Tools

Superabrasive Wheel Grinding Wheels with diamond and cBN are called “Superabrasive Wheels”, to distinguish from conventional wheels such as aluminum oxide and silicon carbide. *cBN (or CBN) = Cubic Boron Nitride

ƑComparison of Superabrasive and Conventional wheel (based on characteristics) ①Thermal Conductivity ②Hardness

2,500 100 90 90 2,000 2,000 80 70 1,500 60 56 1,300 50 1,000 40 30 27 500 20 15

Knoop Hardness GPa 10 67 33 0 0 Thermal Conductivity W/(m·K) Diamond cBN Silicon carbide Alumina Diamond cBN Silicon carbide Alumina (SiC) (Al2O3) (SiC) (Al2O3)

Superabrasives have better thermal conductivity. Superabrasives have higher hardness. (Inhibit temperature rise of workpiece) High efficiency and accuracy as well as low cost process Deterioration risk of work hardness under proper condi- are obtained under proper condition. Also, continuous tion is low. High quality process such as high compressive processing is available due to low frequency of tool change. stress and low damaged layers are obtained.

3 Wheel Figure

ƑAbrasive ƑType of Bond ƑGrit Size Grinding Tools Display Average Type JIS Display Resin B JIS Size (μm) Natural Diamond D Metal M 16 16/20 1190 Synthetic Diamond SD Vitrified V 20 20/30 840 Coated Synthetic Diamond SDC Electro-plated P 30 30/40 590 Cubic Boron Nitride cBN 40 40/50 420 Coated Cubic Boron Nitride cBNC 50 50/60 300 60 60/80 250 80 80/100 177 Synthetic Diamond 100 100/120 149 120 120/140 125 140 140/170 105

170 170/200 88 Wheel / General 200 200/230 74 230 230/270 63 Natural Diamond Resin Bond Metal Bond Coated Synthetic Diamond 270 270/325 50 cBN Abrasive 325 325/400 44 400 37 600 30 800 20 1000 15 1500 10 Monocrystal Polycrystal Coated Monocrystal 2000 8 3000 5 ƑIdentification System of Diamond & cBN Wheel SDC 200 N 100 BS40 3.0

Abrasive Type Bonding Degree Bond Name Grit Size Concentration Thickness of Abrasive Layer

ƑConcentration ƑBond Strength Degree of Concentration Grain Content ct/cm3 (mg/cm3) “N” is standard and indicates the bonding strength of abrasive and bond 150 6．6 (1320) 125 5．5 (1100) Soft Hard 100 4．4 (880) 75 3．3 (660) J L N P R 50 2．2 (440) Notes : 1ct=200mg

ƑMaterial Processed by Diamond or cBN Wheel

Ɣ Cutting Tool Ɣ Electric Parts Ɣ Magnetic Material Ɣ Crystalline Material Ɣ Ceramic Products Ɣ Wear Resistant Metal Ɣ Plastic Ɣ Graphite Ɣ Conventional Wheel Ɣ Cemented Carbide Ɣ Ceramic Ɣ Ferrite Ɣ Glass Ɣ Stone Ɣ Sprayed Metal Ɣ F.R.P. Ɣ Cermet (Aluminum nitride, etc.) Ɣ Rare earth Magnet Ɣ Crystal Ɣ Refractory Material Ɣ Cobalt base Alloy (Grindstone) Ɣ Ceramics Ɣ Silicon Ɣ Quartz Ɣ Tile Ɣ Titanium Carbide Ɣ Jewelry

Diamond (Alumina,etc.) Ɣ Compound Ɣ Sapphire Ɣ Asphalt semiconductor Ɣ Concrete

Ɣ Cutting Tool Ɣ Wear Resistant Tool Ɣ Structural Component Ɣ Corrosion Resistant Metal Ɣ Heat Resistant Metal Ɣ Magnetic Material Ɣ Cast Iron

Ɣ SKH Ɣ SKD Ɣ SCM Ɣ SUS Ɣ SUH Ɣ Dust Core Ɣ SKS Ɣ Sprayed Metal Ɣ SNCM Ɣ Nickel base Alloy Ɣ Alnico

cBN Ɣ SK Ɣ Cobalt base Alloy Ɣ SCr Ɣ Titanium base Alloy Ɣ SUJ

4 Grinding Tools Bond features and applications Wheel Figure

Resin Bond Wheel Metal Bond Wheel The main component of resin bond is thermo- Metal Bond consists of various types of alloys: hardening resin. Phenol resin is mainly used but copper, tin, steel, cobalt, and tungsten. polyimide resin, which has better heat resistance, is MT Bond Wheel applying (our) special metal bond becoming more common. has excellent grinding ability as well as long tool life Our products are widely used in many kinds of ma- and is highly recommended for ceramics, carbide, terial. and cermet.

ŶFeatures ŶFeatures 1. Elastic property of (resin) bond leads to excellent 1. Higher wear resistance and abrasive retention lead surface roughness. to long tool life. 2. Excellent durability of grinding ability for various 2. Good grinding ability on glass and ferrite by brittle kind of materials hard to be ground. (fracturing) mode. Grid (Diamond / cBN) Grid (Diamond / cBN)

Bond Bond (Resin) (Metal)

Core Material (Aluminum Alloy or Steel) Core Material (Aluminum Alloy or Steel) ŶApplications ŶApplications Metal material such as cemented carbide, cermet, Rough grinding for certain material such as glass, ce- and high speed steel ramics, ferrite, semiconductor material, and stone From rough to finish grinding for certain materials such as fine ceramics, ferrite, and glass

5 Wheel Figure

Vitrified Bond Wheel Electroplated Wheel Grinding Tools Vitrified Bond is glass-basd ceramic and has been Abrasives are fixed by Ni plating on the surface of used for conventional grinding wheels through the steeel bodys which have various kind of precise ages. forms. We have abundant lineup : “VITMATE” applying Our products are widely used in many kinds of ma- cBN, “EG WHEEL” for cemented carbide and ce- terial. ramic, and “NANOMATE” which is applicable to super finish grinding of semiconductor materials. Bond features and applications

ŶFeatures ŶFeatures 1. Good grinding ability due to pores 1. Excellent durability of grinding ability due to large 2. Trueing and dressing of VITMATE can be operated protrusion (following good chip discharging proper- with a Rotary Dresser on the machine ty). 3. Special adhesion technology can be applied for 2. Excellent profile maintaining property due to large high speed grinding. number of active grains. 3. Easy to be formed and body is reusable Grid (Diamond / cBN) Bond (nickel plating) Bond Pore (Vitrified)

Grid (Diamond / cBN)

Core Material (Steel) Core Material (Aluminum Alloy, Steel, Ceramics) ŶApplications ŶApplications Steel, cemented carbide, semiconductor material, Form grinding of cemented carbide, ceramics, mag- and ceramics, etc. netic material and steel, etc. Suitable for high efficiency processes of high speed Dry grinding of rubber and FRP, etc. grinding

6 Grinding Tools Truing·Dressing Wheel Figure

ƑAbout Truing and Dressing

Truing and Dressing are important in allowing full grinding ability and effective wheel use.

Truing is wheel forming process Table 1. Method of Truing for Each Type of Diamond and cBN Wheel Applicable Applicable Bond including run-out elimination. Truing Method and Tool Forming Remarks Abrasive (*1 *2) Dia V Possible Rotary Dresser cBN V.B Possible Rotating Dia V Possible Type Metal Wheel Used mostly with Diamond cBN V.B.M Possible cBN wheel; cannot be applied Tool Method Electrodeposition Arbor cBN V.B Not Possible to diamond except Single Point, Multi-point Dresser cBN V.B Not Possible in some cases Impregnated Dresser cBN V.B Not Possible Static Type Block Dresser cBN V.B Possible Electrodeposition Block Dresser cBN V.B.(M) Not Possible Dia B.V.M Possible Rotating Type Grinding Wheel Rotating Type can Conventional cBN B.V.M Possible be used for most diamond and cBN Wheel Method Dia B.V.(M) Not Possible but Static Type is Static Type Stick cBN B.V.(M) Not Possible very limited Dia B Not Possible Rotating Type Soft Steel Roll Simple way ap- Soft Steel cBN B Not Possible plied from long Method Dia B Not Possible ago; forming is not Static Type Soft Steel Block possible cBN B Not Possible Dia B.V.M Not Possible Loose Abrasive Method Lapping cBN B.V.M Not Possible Specialized equip- Dia V Possible Crash Method Steel Roll ment is required cBN V Possible Dia M Possible Electro-discharge Machining Electrode cBN M Possible *1 : B: Resin Bond , M: Metal Bond, V: Vitrified Bond *2 : Order of easiness for truing; ( ) is not general

Fig.1. Illustration of Truing and Dressing

Bond Bond Abrasive Abrasive

Truing Dressing

Dressing is abrasive projecting process by Table 2. Method of Dressing for Each Type of Diamond and cBN Wheel removing bond and chips on wheel surface. Dressing Method and Tool Applicable Abrasive Applicable Bond

Dia V Rotary Dresser Rotating cBN V Type Dia V Metal Wheel Diamond Tool Method cBN V Single Point, Multi-point Dresser cBN V Static Impregnated Dresser cBN V Type Block Dresser cBN V Rotating Dia B.V.M Grinding Wheel Type cBN B.V.M Conventional Wheel Method Static Dia B.V.M Stick Type cBN B.V.M Rotating Dia B Soft Steel Roll Type cBN B Soft Steel Method Static Dia B Soft Steel Block Type cBN B Lapping Dia, cBN B.V.M Free Abrasive 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 Order of easiness for dressing

7 Wheel Figure

ƑIdentification Method of Wheel Shape Grinding Tools

1 Standard Body Shape 2 Cross Sectional Shape of Abrasive Layer

1 9 A D FF L QQ

2 11 AH DD G LL S 45° ~90°

3 12 B E H M U

under 45° 4 14 C EE J P V

6 15 CH F K Q Y Wheel Shape 1 2 3 4

6 A 2 C

4 Modification & Symbol

Symbol Modification Diagram

B Spot Facing Hole

C Countersinking Hole 3 Abrasive Layer Position & Symbol Reference to B H Straight Hole Symbol Position Diagram

M Straight & Threading Hole 1 Periphery P Relief at One Side

Insert of Q Abrasive Layer

2 Side R Relief at Both Sides

Segmented 3 Both Sides S Abrasive Layer

Incline or 4 Roundness, Inside

Incline or 5 Roundness, Outside Slot Segmented SS Abrasive Layer

6 Part of Periphery T Threading Hole

Reverse Attachment 7 Part of Side V of Abrasive Layer

With Shaft 8 Whole W

Y Reverse Insert 9 Edge of Abrasive layer

10 Internal

8 Grinding Tools Standard Wheel Shape Wheel Figure

ƑStandard Wheel Shape 1

1A1 Straight 1A1R Cutting

D D X X T T H H

3A1/14A1 Straight with Boss 1A1RSS Cutting Saw

D D X X T T H U

1F1/1FF1 Straight with R 1V1 Straight with Angle D X D X T

R T

H V H R

1EE1/1E6Q V Face 4B2 One Side V Face D X D W

V V

H T X T V H H

1Q1/1L1 Chipbreaker 9U1 U-shaped Straight D X R D W T X X T

H H R

1DD6Y Centering 1FF6Y/1EE6Y/1LL6Y/1DD6Y Pencil Edge

D1 D1 D D X X Û U T V U T H H 45Û

9 Wheel Figure

ƑStandard Wheel Shape 2 Grinding Tools

6A2 Plain Cup 6A2S Segment Cup

D D

W W X X T T

H H

11A2/11B2 Flair Cup 11C9/11Y9 L-shaped Flair Cup Standard Wheel Shape D D W X

W X T

H X T H

6A9/11V9 Corner Cup 12A2 Dish

D D W X

W X T

H T H

11V2S Wedge-shaped Segment Cup 9A3 Both Side Cup

D D W Û W X X T T

H H

3A2 Core Drill 3V2T Chamfering L L Use together with Core Drill（ 3A2） B X W X W D S D

3F2 Curve Generator W Internal with Shank

X W

X W X W L T D D D X

X W X W Y D D D

10 Grinding Tools Flute MAX

Flute MAX ƑCreep feed grinding of cemented carbide ◆ Conditions Workpiece Cemented carbide Wheel specification SDC140-100B Wheel speed V=1600m/min Work speed F=80mm/min Depth of cut a=0.5mm/pass Coolant water-soluble

Conventional resin bond wheel 50 Flute MAX 40

10 Grinding force Fn (N/mm)

0 ×100 02 4 6 8 10 12 14 16 18 20 22 Cumulative stock removal (mm3/mm) Suitable for grooving with water-soluble coolant ◆ Result Flute MAX applies super heat resistant resin with a Compared to conventinal resin bond wheel Flute MAX can maintain low grinding force and cutting ability. 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 ƑFlute Grinding of Cemented Carbide Endmill other tools. ◆ Conditions Workpiece 8D 2-flute endmill Wheel specification SDC270-100B ŶFeatures Wheel speed V=1,600m/min Super heat resitant resin helps to reduce deteriora- Depth of cut a=1.5mm (1st time) tion under high temperature. 0.5mm (2nd time) Excellent cutting ability and shape retention even Coolant water-soluble for heavy load grinding such as creep feed grinding. High feed rate and long dressing interval compared 350 to conventional wheels which lead to high efficinecy 300 and cost reduction. 250 200 ŶApplications 150 Grooving of endmills, drills and reamers 100 Feed Ratio (mm/min) 50 Chipbreaker grinding of inserts 0 Heavy grinding of various tools including special Conventional Flute MAX steel tools resin bond wheel ◆ Result Ƒ3 different bond types Flute MAX can achieve grinding by 4 times faster feed ratio Bond grade Special feature than conventional resin bond wheel in same tool life. L Superior cutting ability N Standard P Superior shape retention

11 Flute Master

Flute Master® ƑFlute Grinding Grinding Tools

ƑRelation between grinding force and feed rate 1) Wheel Specification ①Resin : SDC325N100B ②CBM-L : SD325L100CBM 2) Work Material : Cemented Carbide 3) Conditions : Wheel Peripheral Speed : 1500m/min D.O.C. : 3mm Coolant : Oil-based Machine : Horizontal spindle surface grinder

Grinding force vs feed rate ® 160

140 Partial wear confirmed Flute Master ĺ 120 100 N/mm

Suitable for grooving with oil-based coolant 80 Normal Processing 60 Flute Master was created to exhibit excellent heat 40 Resin CBM-L 20 resistance of metal bond and surpasses the grinding Grinding force 0 ability of the resin bond wheel. 50 75 100 125 )HHG5DWHPPPLQĺ

ŶFeatures ƑGrinding performance Newly developed metal bond has both excellent 1) Wheel Specification ①Resin : BN140-100B grinding ability and provides long tool life. It also ②CBM-L : BN140L-100CBM increases grinding efficiency, especially when used ③CBM-P : BN140P-100CBM 2) Work Material : SKH51(HRC60) with oil-based coolant. 3) Conditions : Wheel Peripheral Speed : 1500m/min D.O.C. : 1mm Feed rate : 40mm/min ŶApplications Coolant : Oil-based Flute grinding of endmills, drills and reamers Machine : Horizontal spindle surface grinder Chipbreaker grinding of inserts Comparison of grinding quantities 1500 Heavy duty grinding of various tools, including special steel tools 1000

500 Quantity ground Bond Line Up 0 Ƒ Resin CBM-L CBM-P

Comparison of surface roughness 1.5 Long CBM-P 1.0 CBM-N Ryum 0.5 CBM-L

Surface roughness 0.0 Resin CBM-L CBM-P Tool life Tool Comparison of grinding force Grinding efficiency High 60

N/mm 20 Grinding force 0 Resin CBM-L CBM-P

12 Grinding Tools Hybrid Wheel

Hybrid Wheel ƑType and standard size Straight Type

D X

Item Number D T X H HS050 50 HS075 75 HS100 100 HS125 125 3,5,8,10, HS150 150 15,20 HS175 175 HS180 180 3,5 HS200 200

HS250 250 As requested HS300 300 Suitable for cermet grinding HS350 350 10,15,20, HS400 400 25,30 HS500 500 ŶFeatures HS600 600 The Hybrid Wheel was developed for high-efficinecy Cup Type

grinding of cermet, a material that is hard-to-cut. D W X ƔExcellent grinding ability and long tool life due to effect by micro-segment of special metal bond T ƔGood surface roughness and minimal chipping due to resin bond matrix H

Item Number DTXH HC050 50 HC075 75 3,5,8,10 HC100 100 HC125 125 HC150 150 HC175 175 3,5 HC200 200 ƑMicro-segment structure HC250 250 5,8,10,15 As requested HC300 300 HC350 350 HC400 400 HC500 500 *All cup wheel types are available ƑPerformance of Hybrid Wheel Hybrid Conventional resin bond Size Ø350×12W×6X, 6A2 ŶApplications Wheel Peripheral grinding of cermet, surface honing, Specification SD325-HB SDC325R75B Ƒ Work Size 12.7 ×3,175 grooving and chipbreaker grinding, etc. Material Specification TIC-TIN Cermet Various grinding including cemented carbide and Machine TA outer grinder Peripheral Speed 1600m/min ceramics Grinding Condition Cutting Side 3mm/min Speed 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

13 Flank Master

Flank Master® (Peripheral grinding and finish grinding of cutting edge) Grinding Tools For carbide / cermet cutting tools Type-R For PCD / PcBN cutting tools Type-V

ŶFeatures ŶFeatures Applies special metal filler to improve heat radiation Combination of bond which has superior grit reten- drastically. Realize good cutting ability and long tool tion and pore structure realize good grinding ability life by reducing heat deterioration of grit and bond and wear resistance that lead to high-efficiency and from cutting heat. high-accuracy grinding

ŶPeripheral grinding of cemented carbide insert ŶPeripheral grinding of PCD insert 1. Conditions 1. Conditions 1) Machine : NC peripheral grinder 1) Machine : NC outer grinder 2) Workpiece : carbide 2) Workpiece : PCD (Polycrystalline Diamond) 3) Coolant : water-soluble 3) Coolant : water-soluble 4) Wheel 4) Wheel SD400N100BFX (Flank Master Type-R) SD2000N2-VPD (Flank Master Type-V) SD400-100B (made by another company) 2. Results

2. Results Flank Master Type-V Another company's product

150 120 100 100 80 60 50 40 0 20 Flank Master Another company's 0

Machining efficiency (Index) Machining efficiency Type-R product Chipping Cutting Cleaning rejection rate speed time *Another company's product shown with index of 100 *Another company's product shown with index of 100

120 Cutting surface comparison 100 80 Chipping 60 40 20 Tool life (Index) Tool 0 Flank Master Another company's Type-R product

*Another company's product shown with index of 100 Flank Master Type-V Another company's product

14 Grinding Tools VITMATE

VITMATE® ŶFeatures Achieves high efficiency and low cost grinding thanks to high grit retention Easy to use with improved dressing performance.

ŶApplications Industries : Automotive, bearing, household appliances, tools machinery, gear, mold&die Work piece : Cam, crank shaft, injection needle, rocker arm, compressor, bearing, ball screw, motor, etc.

ƑAngular grinding ƑHigh-speed contouring grinding

End Face Grinding

O.D.Grinding Ø37 Ø35 Ø45 Ø60 200

1. Conditions 1. Conditions 1) Machine : High-speed cylindrical grinder 1) Machine : Angular grinder 2) Wheel : Size : Ø400×10U 2) Wheel : Size : Ø350×22U Specification : BN120M200VE2 Specification : BN120N175VX5 3) Workpiece : SCM435 (HRC60) 3) Dresser : SD40-75M 4) Conditions 4) Workpiece : SCM425 (HRC60) Peripheral speed : 160m/s 5) Conditions D.O.C. : Ø0.2mm Peripheral speed : 80m/s Feed rate : 300mm/min Stock allowance : O.D. Ø0.28mm Coolant : Water-soluble End Face 0.15mm Coolant : Water-soluble 2. Results

2. Results Surface Roughness 1.5 Surface Roughness 1 6 m) μ 0.5

m) 4 Ry ( μ 2 0 Ry ( Surface Roughness VITMATE Conventional wheel 0

Surface Roughness VITMATE Conventional wheel Tool Cost 150 Machining Time 60 100 40

(Index) 50 Tool Cost Tool (sec) 20 0 0 Machining Time VITMATE Conventional wheel VITMATE Conventional wheel *Another company's product shown with index of 100

15 EG Wheel

EG Wheel ƑSurface grinding ƔConditions Grinding Tools Workpiece : Ceramics post Alumina Ƒ60 × 360L Ɣ Application Example 1. Machine : Surface grinder PSG-63DXNC 2. Wheel : Ø300-15U 1) #270 resin bond wheel 2) SD230G100C3 3. Rotary Dresser : Ø150-10U SD40-M 4. Dresser Drive Unit : SGS-50 (ALMT)

Ɣ Result 1. 6 times productivity than conventional diamond resin bond wheel ŶFeatures 2. Decreases dressing and truing time from 60min. Easy dressing and truing on a grinder with special to 5min. diamond rotary dresser Excellent run-out and form accuracy in short time on a grinder Accurate arrangement of cutting edges for surface roughness, productivity and wheel life

Applications Ŷ 60 Industries : Machine tool, household appliances, automotive, bearing

Work piece : Ceramics and carbide 360

ƑProduction ranges Outer diameter Ø3~750mm Surface Roughness Accuracy Straightness T size 3~300mm m) X size 2~15mm μ

m) 4.0 μ Grit size SD (#80~#3000) 3.0

2.0

1.0 Straightness (

Surface Roughness ( 0 EG Wheel Conventional resin wheel

16 17 semi-conductor, materials. andother electrics, grindhar possibleto and makes bond, combinedwithaspecial offers lower grinding force and improves grinding opera- grinding andimproves force grinding lower offers tions. Ƒ on workpieceandgrindingmachine. Low grindingforcesresultinreductionofeachloadapplied Ƒ or slicedwafer Suitable forroughgrindingofdeposited Strong diamond grit retention retention diamondgrit Strong Achieves a flatness of less than less 1 of aflatness Achieves o iio ForSilicon For Silicon aoaeVHatNanomate Premium Nanomate V-Heart Grinding Force is 1/10 of resin bonding wheel bonding resin 1/10 is Grindingof Force Grinding Force Nanomate Grinding Force Grinding Tools Grinding Force High

Nanomate V-Heart Low High Process quantity 0040 008000 6000 4000 2000 d-to-cut materials,includingd-to-cut Increase ly-shaped diamondlayer,ly-shaped and high porosity vitrified and highporosity Nanomate Special metal Resin Resin bond μ m on Ø Continuous GrindingContinuous 300 Si wafer 300 Siwafer Grit Size wafer andpreventcracksonathinlayerdevicewafer. brittle materialsuchaspolish-reductionofØ300mmsilicon and productiontechnologyhasallowedsuper-finegrinding. wheels. Application ofbothacquiredmaterialtechnology tionized theconventionalwisdomwithregardtogrinding and backsidegrindingofdevicewafer Suitable formirrorfinishgrindingofwafer Ƒ Ƒ Its effectiveness toreduceagrindingdamagedlayerof Super-fine diamondgritandsuper-fineceramicsrevolu- Relation between grit size and surface roughness surface and size grit between Relation Grinding resultbySD8000Nanomate

PV (nm) 30 50 35 45 40 20 25 10 15 0 5 0050 8000 5000 3000 General purposesur- face grinder Grit Size(mesh) High precision sur- precision High face grinder 0 1 2 3 4 5 6 7 8 9 10

Ra (nm) Nanomate

Nanomate Premium Grinding Tools For SiC finish process For SiC and Sapphire rough process

Suitable for wafer grinding of semicon- Suitable for rough and semi-finish grind- ductor power device ing of semiconductor power device

Combining diamond grit and vitrified bond with suit- Newly developed vitrified bond for rough process has able ratio to obtain best grit clearance for efficient high grit retention and pore which realize high efficient con- grinding. Continuous grinding of monocrystal SiC is tinuous process. now available. Suitable for hard-to-cut material such as sapphire and SiC Especially, superabrasive wheel can process with and can feed 2 to 3 times compared to conventional wheel. same feed rate as the one for silicon wafer grinding to obrain extremely smooth surface. ƑGrinding result of 4 inch sapphire wafer Grit size and work surface (SiC wafer) Continuous process with no dressing is possible Ƒ 500 500 ƔSD3000 (feed 40ȝm/min) ƔSD8000 (feed 20ȝm/min) 400 400 Surface roughness 300 300

200 200 Grinding force: 100 100 Conventional wheel Grinding force Fn (N) Nanomate premium

Surface roughness Ra (nm) Surface roughness: 0 0 Conventional wheel 12345678910 Nanomate premium Process quantity

Surface of workpiece Normal force and surface roughness (Spec : SD400) ƑHigh efficient grinding results of 3 inch SiC wafer

Possible to increase feed rate for high efficient process 10 10 9 9 ȝP ȝP 8 8 7 7 6 6 5 5 Damage of surface Conventional 4 wheel 4 3 3

Current value (A) 2 2 1 1 Surface roughness Ra (nm) 0 0 Current value 40 80 120 Surface roughness Ra Feed rate F (ȝm/min)

100nm 100nm Current value and surface roughness (Spec : SD2000)

18 19 ing wheel MT BondWheel-pursuingtheidealgrind- ous ceramics,andsteels. recommended forthesurfacegrindingofglass,vari- cermet, andhighspeedsteel.MT30,40,50are eration ofvarioustoolssuchascementedcarbide, Ŷ which sustainsitsgrindingability. grinding andcreepfeedbyprofiledwheel, wheel isfornon-ferrousmaterials. bide, cermet,andquartz,ontheotherhand,cBN vantages ofbothresinbondandmetalbond. tured toreachoptimumgrindingability, fusingthead- MT10 and20arerecommendedforthegrindingop- MT BondWheelisrecommended forthesurface The DiamondWheelefficiently grindsceramic,car- MT Bondisanewmetal bondwhichismanufac- MT BondDiamond&cBNWheels Suitable forvariousworkpieces MT BondWheel Grinding Tools

Surface Roughness Fine Grinding Performance Conventional wheel MT BondWheel Good Ɣ Ɣ*ULQGLQJFRQGLWLRQV Ɣ Ƒ Ƒ Ƒ Grinding conditions Grinding conditions D.O.C. :a=1mm Work Speed:F=60m/min Wheel Speed:V=1600m/min Workpiece :SiliconNitride '2&D ȝP Work Speed: F=10m/min Wheel Speed:V=1760m/min Workpiece :SiliconNitride '2&D ȝP Work Speed:F=10m/min Wheel Speed:V=1,650m/min Workpiece :SiliconNitride Creep feedgrinding Surface grinding Grinding abilityofeachgradesMT Bond Result Result Data.3 Data.1 Data.2 than theresinbondwheel The grindingforce(normalforce)is40%lower Grinding Force (N/mm) #230,#400, and#800). force (comparisonisbetweengritsizes size. The finergritproduces alowergrinding force thanresinbondwheelwiththesamegrit MT Bond Wheelshows20%lowergrinding 0400 10 15 20 25 30 35 40 45 50

0 5 Grinding Force (N/mm) Grinding Force (N/mm) 100 150 200 10 15 20 25 30 50 0 5 0 T0M4 T0M2 MT10 MT20 MT30 MT40 MT50 #800-MT #140-MT #400-MT #230-MT #140-B Grinding ratio Grinding Ft´ Fn´ #230-B 0 50 100 150 200 250 300 350

Grinding Ratio MB SPARK

MB SPARK ƑHigh Truing Performance

ƔMB SPARK allows for shorter work time on grinder quick Grinding Tools truing with high accuracy using special low-melting metal bond suitable for electro-discharge truing. ƔFurther benefits are attained with fine grit of superabrasive applied. Excellent flatness acquired in a short time frame. Ɣ&RPSDULVRQRI7UXLQJ3HUIRUPDQFH

40 WA truing

20 Electro-discharge truing

Trueing Time (min.) Time Trueing 10

MB SPARK Resin bond wheel #230-MED #140-B Double disc metal bond wheel for electro-discharge truing SPARK Ɣ3 times longer tool life than conventional resin bond wheel

The next generation of double disc grind- Electro-discharge ing systems Truing Machine : Koyo Machinery Suitable for surface quality improvement of elements used in automotive and household appliance in Discharge Electrode the progress of energy saving and miniaturization. Extends the truing interval in combination with elec- ƑLong Lasting Quality tro-discharge truing compared with conventional resin MB SPARK has higher wear resistance than conventional bond wheel. resin bond wheel and keeps flatness of super abrasive layer longer. Truing interval is extended and suitable for automat- ŶFeatures ed production line. 1. Metal bond wheel with excellent electro-discharge Ɣ&RPSDULVRQRI*ULQGLQJ&DSDELLW\

truing capability. Easy high-accuracy truing on a Workpiece : Oil pump component 40 m) μ grinder. 35 Truing limit 2. Long lasting cutting performance and high-wear re- 30 sistance. 25 3. Less industrial waste-stops sludge produced from 20 15 wheel during truing. 10 Resin bond wheel 5 MB SPARK

Super Abrasive Layer Wear ( Abrasive Layer Wear Super 0 Ɣ*ULQGLQJ&RQGLWLRQV 0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 # of Ground Pieces Grinder Koyo KVD-300 Ø305-75W-3X-Ø80H Grinding Wheel MB SPARK #230-MED ƑHigh Grindability Resin Bond Wheel #140-B MB SPARK applies special metal bond suitable for double Oil pump component disc grinding. Its characteristic of high grit retention and sur- Workpiece Powdermetal SMF4040 face retention of abrasive layer show exellent cutting ability Upper : 1500min-1 (C.C.W) Wheel Rotation to achieve improvement of process. Lower : 1500min-1 (C.C.W)

Total Stock Removal 0.2mm (both sides) 6 Rough Stock Removal 0.19mm (both sides) Resin bond wheel Rough Grinding Speed 0.035mm/sec 4 MB SPARK Finish Stock Removal 0.01mm (both sides) Finish Grinding Speed 0.015mm/sec 2 Spark out 2sec

Grinding Spindle (A) 0 Load Current Value of Load Current Value 0 20 40 60 80 100 120 Grinding Amount (cm3)

20 Grinding Tools DPG Wheel

ƑGrinding Performance of DPG wheel (MDP bond) DPG Wheel Patented Product Grinding Rate 10 Grinding ratio

6 Index 4

0 MDP1 MDP2 MDP3 MDP4 MDP5

ƑCassette Plate (design registration) Ɣ7RS)DFH Mounting Hole is Div ible Cassette Diamond/cBN Lapping Plate DPG Wheel ŶFeatures 1. Environment DPG (Diamond Pellet Grinding) Wheel is a environ- mentally friendly fixed abrasive tool ,enable replacing loose abrasive processing, Diamond Pellet 1) Reduce industrial waste dramatically 2) No clean-up with chloric organic solvent 3) Clean operating environment ❶Reduction of replacing process for cassette plate 1RGHWDFKLQJEDVHSODWH 2. High Efficiency 'LYLVLEOHFDVVHWWHIL[HGRQEDVHSODWH 5 to 100 times faster grinding speed compared to 6KRUWGUHVVLQJWLPH loose abrasive lapping. (20minutes : 9B, 1~2 hours : 16B) 3. Cost Reduction ❷Pellet pattern keeps high accuracy grinding Reduce maintenance costs with long lasting plate and 'LYLVLEOHFDVVHWWHGHVLJQHGIRUSHOOHWOD\RXW gear. 6HDPVQHYHULQWHUIHUHZLWKWKHGHQVLW\RISHOOHWGLVWULEXWLRQ 4. Process Reduction ❸Free layout of coolant hole for top plate Integrate pre-grinding and lapping into one process &RRODQWSRRORQFODPSIDFH

Size Max. Dia. Min. Dia. Grinding Speed (μm/min) 0.25 100 4B 299 117 Surface Roughness (Ra μm) 5B 389 213 m)

0.2 μ 80 6B 380 148

m/min) 6B/9B 650 384 μ 0.15 9B 637 218 60 12B 1058 360 0.1 13B 950 274 40 15B 1022 346

Grinding Speed ( 16B 1127 270 Surface Roughness (Ra 20 0.05 18B 1260 294 20B 1355 458 0 0 24B 1592 554 DPG Lapping 28B 1864 660 * Special sizes also available

21 Super Sizing, CMP Conditioner

Super Sizing CMP Conditioner Grinding Tools

Ø270mm

Ø360mm

Ø100mm

Highly efficient superabrasive reamer for ①High quality diamond high precision one-pass hole machining ƔScratches caused by diamond crash can be mini- mized ŶFeatures ƔUniformly-shaped diamond leads stable perfor- 1. Capable of one-pass hole machining mance 2. High accuracy (roughness roundness cylindricity) ②High precision body 3. Reduction of rolled edge around lubricant hole or Ɣ8QLIRUPFRQWDFWZLWKSROLVKLQJSDG keyway ③High precision electro-plating 4. Skill is not required Ɣ&RPSOHWHVLQJOHGLDPRQGOD\HU Ɣ8QLIRUPGLVWULEXWLRQRIWKHGLDPRQGJULWFUHDWHV ŶApplications the best surface condition of the pad and stable Hole finish machining of cast iron hydraulic com- polishing performance ponet and automotive parts. ④Dedicated production line Ɣ&03&RQGLWLRQHULVSURGXFHGRQDOLQHLVRODWHG ŶPossible Manufacturing Range from other tools Abrasive Diamond or cBN Grit size #60/80~#100/120 NS-1 (R type)

Tool dia. Ø5~40 ±0.002mm ALMT NS-1 Run-out 0.005mm or less pad * Some items even in its range cannot be produced depending on specifiactions. NS-2 (Angular type)

ŶMachining Application ALMT NS-2 Workpiece : Hole finish machining of hydraulic components pad : Dia. Ø18.5 H6 (+0.13,0) : FC250 or equivalent Conventional

Tool specification : cBN80-P Conventional conditioner

Tool size : Ø18.5 0,+0.005 pad Conditions : Tool peripheral speed 7.6m/min : Feed rate 26mm/min : Removal stock Ø0.01mm : Coolant Straight oil ALMT NS-1 Results : Hole roundness 0.002mm or less : Hole cylindricity 0.004mm ALMT NS-2 Pad Cut Rate : Roughness Ry2.6μm Conventional

Conditioning Time

22 Grinding Tools Electro-plated Internal Wheel

Diamond/cBN mounted points for internal grinding

W11 W12

L L

T C0.5 1 C0.5 T

ØD ØY ＋0 Ød ＋0 －0.02 ØD ØY －0.02

CD code D T Ɛ L Grit # CD code D TdL 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 5 270 3 #120 W11007 SD 0.7 3 8 40 #200 W12060 SD 6.0 8 370 3 #120 W11008 SD 0.8 3 10 40 #200 W12070 SD 7.0 8 470 6 #120 W11009 SD 0.9 3 10 40 #200 W12080 SD 8.0 8 570 6 #120 SD 1.0 3 10 40 #200 W12090 SD 9.0 8 670 6 #120 W11010 LD 1.0 3 15 40 #200 W12100 SD 10.0 10 7100 6 #120 SD 1.2 5 10 45 #200 W12120 SD 12.0 10 9100 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 Ŷ:KHQRUGHULQJŶ SD 1.7 5 13 45 #200 W11017 LD 1.7 5 20 45 #200 Ɣ3OHDVHLQVWUXFW&'FRGH SD 2.0 5 13 45 #200 W11020 Ɣ$OOLWHPVDUHLQVWRFN LD 2.0 5 20 45 #200 Ɣ6SHFLDOVSHFLILFDWLRQVDYDLODEOHXSRQUHTXHVW SD 2.3 5 13 45 #200 W11023 3OHDVHLQVWUXFWUHTXLUHGVL]HV LD 2.3 5 20 45 #200 H[ W12050 SD L=100, Y=10, ..... SD 2.5 5 13 45 #120 W11025 LD 2.5 5 20 45 #120 Ɣ&RGHRIPRXQWHGSRLQW SD 3.0 5 15 50 #120 W11030 W12050 SD LD 3.0 5 22 50 #120 D='LDPRQG * SD 6.0 5 20 65 #120 W11060 % F%1 LD 6.0 5 27 65 #120 (Y=Ø3, But *Y=Ø6)

23 Dresser

Rotary Dresser is a Diamond tool to form a conventional or cBN grinding wheels. Complex and Precise profile accuracy.

RZ Type SZ Type 2XUDGYDQFHGDQGXQLTXHWHFKQRORJ\LQ $URWDU\GUHVVHUZLWKGLDPRQGJULWVDU- KLJKSUHFLVLRQHOHFWURGHSRVLWLRQPDNHLWSRV- UDQJHGUHJXODUO\PDGHE\WKHUHYHUVH VLEOHWRDFFRPPRGDWHFRPSOH[DQGILQHSUR- SODWLQJPHWKRG&RQFHQWUDWLRQRIWKHGL- ILOHV'LDPRQGJULWVZKLFKIL[HG DPRQGFDQEHFRQWUROOHGDF- E\UHYHUVHSODWLQJPHWKRGDUH FRUGLQJWRUHTXLUHPHQWV7KH DUUDQJHGUDQGRPO\DQGLWVFRQ- 6=7\SHSURYLGHVHIILFLHQW VHQWUDWLRQLVYHU\KLJKVRLWLV SOXQJHGUHVVLQJRIODUJHVL]H DOVRVXLWDEOHIRUORQJHUOLIHDSSOL- URWDU\GUHVVHUV FDWLRQV9DULRXVRSWLRQDOVSHFLIL- FDWLRQVDUHDOVRDYDLODEOH

Z Type SX Type X Type

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

24 Dresser Specification Rotary Dressers

ƑProcess grouping & possible production ranges ŶProcess grouping Item RZ Type SZ Type Z Type SX Type X Type Manufacturing Method Electro-deposition Electro-deposition Electro-plating Sintering Sintering Diamond Grit Distribution Random Regular Random Regular Random Applicable Grit Size #20~#140 #16~#20 #30~#140 #16~#20 #30~#80 Complex Cup Profile Form Form Form Fine Straight Plunge Plunge Dress Method Plunge Plunge Traverse Traverse Travese Bearing Shafts Gear Grinding Turbine Blades Internal Grinding Principal use Ɣ Ɣ Ɣ Ɣ Ɣ ƔInjection Needles ƔCamshafts ƔCenterless Grinding Profile accuracy ◎ ○ ○ ○ ー Surface Roughness ◎ ○ ○ ○ △ Dressing Force ○ ◎ ○ ◎ ◎ Highest precision/ Large diameter/ Any concentration settable/ Major Features Gear Grinding Consistant dressing ability Fine profile/Complex profile High dressing ability High dressing ability

ŶPossible production ranges ・Ranges vary depending on profile or specification etc 50 100 150 200 250 300 (mm) O.D. Ø50~Ø200 RZ Type Width 200 O.D. Ø50~Ø200 SZ Type Width 200 O.D. Ø10~Ø200 Z Type Width 200 O.D. Ø20~Ø180 SX Type Width 120 O.D. Ø20~Ø300 X Type Width 150

ƑOutline of Production Processes for Rotary Dressers Electro-deposition Method / RZ・SZ Type Electro-plating Method / Z Type Sintering Method / SX Type As the product is processed under Diamond is fixed directly on the Surface of the diamond layer is room temperature, the accuracy is body and finished by on the sur- lapped in the final process to not changed by thermal expansion. face of diamond layer. achieve specified accuracy.

Diamond Setting Machining base Diamond Setting

Plating Sintering 25ÛC 1000ÛC

（+） Diamond Setting

Setting Body Machining Body

Machining Body Lapping Lapping

25 Rotary Dressers

ƑTolerances of Rotary Dresser Designs (mm) M W U Dresser L Z Y

U Value W Value Y Value M Value RZ Type ≧10 RZ Type ≧0.5Z RZ Type ≧10 ≧ L SZ Type ≧10 SZ Type ≧0.5Z SZ Type ≧10 ≧ L SX Type ≧ 3 SX Type ≧ 4Z SX Type ≧ 4 ≧0.5L Z Type ≧ 3 Z Type ≧ 4Z Z Type ≧ 4 ≧0.5L Specification X Type ≧ 3 X Type ≧ 2Z X Type ≧ 4 ≧0.5L

PPP convex R *Convex R Value *Concave R Value P Value concave R convex R RZ Type ≧0.1 ≧0.03 RZ Type ≧0.3 concave R SZ Type ≧0.2 ≧0.15 SX Type ≧0.2 ≧0.15 Z Type ≧0.3 ≧0.3 *Value depending on diamond grain sizes

ƑAccuracy of Rotary Dressers Other tolerances available upon request Item Factor Symbol Accuracy (mm) Illustration

Runout 0.005 Profile 0.005 A LL

Width L ± 0.005 S

Radius R ± 0.002 0.002

R R R Profile Step S ± 0.001

Contour 0.002 0.002 ș Angle ș ± 2´

nP Straightness 0.002 PPP

Pitch P ± 0.002 Accumulative Pitch nP ± 0.004

Bore ØH + 0.005 - 0 0.002

Profile 0.002 A Parallel 0.002 Control Body 0.002 Profile Perpendicularity 0.002

A Runout 0.002 ØH

26 Dresser 6SHFLILFDWLRQ Rotary Dressers

Ƒ2SWLRQDO6SHFLILFDWLRQVRI5RWDU\'UHVVHUV Various options available upon request *Availability depending on profile or specification 2SWLRQDO6SHFLILFDWLRQVIRU5=7\SH 2SWLRQDO6SHFLILFDWLRQVIRU6;7\SH ,PSURYHG'UHVVLQJ$ELOLW\ IRUIDVWGUHVVLQJ )RU,PSURYLQJ:HDU5HVLVWDQFH Ɣ*% FRQWUROOHGGLDPRQGFRQFHQWUDWLRQ Ɣ6XSHU+LJK&RQFHQWUDWLRQ High dressing rate with lower concentration by setting the By the unique pattern of diamond setting, maximum 100 glass balls for hard-to-concentration control electro-depo- pcs/cm2 diamond stones provides longer life. sition type. Ɣ6WURQJ Ɣ6KDUSW\SH FRQWUROOHGGLDPRQGSURMHFWLRQ Reinforcing the peak of convex portion by pre-shaped di- Our unique process not by etching the bond layer realiz- amond stones leads stable accuracy and high wear re- es the diamond projection control without pulling-off the sistance as same as RZ type. diamond grit. ƔRZ-ACROSS® FRQWUROOHGGLDPRQGFRQFHQWUDWLRQ Improves the discharge of chips and coolant 2SWLRQDO6SHFLILFDWLRQVIRU9LWULILHGF%1:KHHOV 637\SH 6WDEOHSHUIRUPDQFHDQGORQJHUOLIH Ɣ63 Ŷ RZ-ACROSS® Surface and Profile Special development for high-wear-proof vitrified and cBN forming wheels performing stable dressing as well as long life. Available both for RZ and SX.

1000

800

600 120 400 Dress Ratio 100 200 0 80 SP Standard

Ɣ3RO\FU\VWDOOLQH3ULVP'LDPRQG 60 Product : Crown dresser Arranging isotropic poly- Grinding force (Index) crystalline prism dia- 40 RZ-ACROSS® Sharp GB Standard mond provides stable tool life and performance solving the problem of short life and instability 2. ,PSURYLQJ:HDU5HVLWDQFH IRUORQJHUOLIH caused by anisotropy and cleavage characteristic of mono-crystal diamond. Ɣ6WURQJ Reinforcing the peak of convex portion by pre-shaped Ŷ'UHVVLQJ([DPSOH diamond stones leads stable accuracy and high wear re- Ɣ'UHVVHU0RQRFU\VWDOOLQH3RO\FU\VWDOOLQH sistance. Ɣ'UHVVLQJ&RQGWLRQV Wheel specs : cBN230G125V3 Ø30×20×5 1200min-1 RD specification : 0.4 2L 25pcs Ø25×18 250min-1 Dressing unit : Toolpet Feed rate : 240mm/min D.O.C. : 0.002mm/pass (Total 1.0mm in 500 dressing cycles)

Ɣ5HVXOWV :HDU9ROXPH ↑ 100

50 Index 0 Polycrystalline Mono-crystalline *Mono crystalline shown with index of 100.

27 Rotary Dressers

Ƒ,QVSHFWLRQRI5RWDU\'UHVVHUV For higher accuracy・・・ Required accuracy of rotary dressers is becoming more strict, ranging from microns to submicrons. To ensure re- Dresser quired accuracy, we have established an excellent inspection system with the most up-to-date equipment.

'HVFULSWLRQRI,QVSHFWLRQ ŶBody accuracy Ŷ 1. Bore...... (Air micrometer) ŶInspection with transfer test pieces 2. Parallelism, squareness ...... (Roundness measuring equipment) 1. Measuring dimensional accuracy and profile 3. Reference surface(controlØ) runout...... (Roundness measuring equipment) ...... (tool microscope, profile measuring equipment, projector) 4. Profile runout ...... (Roundness measuring equipment) 2. Surface roughness ...... (surface roughness tester) ŶSlip Test Results An inspection sheet showing measurements taken by the transfer test is attached.

5RWDU\'UHVVHU &RXSRQ &RXSRQ 3ODWH &\OLQGULFDO Inner diameter 6SHFLILFDWLRQ Air micrometer Runout-reference surface Roundness measuring equipment

Profile Tool microscope Profile measuring equipment Profile Profile Projector Runout-profile Tool microscope Profile measuring equipment Roundness measuring equipment Profile Projector Surface roughness Surface roughness tester Surface roughness Surface roughness tester

Ƒ5HFRPPHQGHG'UHVVLQJ&RQGLWLRQV Ŷ3OXQJH'UHVV &RQYHQWLRQDO*ULQGLQJ:KHHO +DUG&RQYHQWLRQDO*ULQGLQJ:KHHO F%1:KHHO 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 aȝPUHYRIZKHHO aȝPUHYRIZKHHO aȝPUHYRIZKHHO Dress Out 0~3 sec. 0~3 sec. 0~3 sec.

Ŷ7UDYHUVH'UHVV &RQYHQWLRQDO*ULQGLQJ:KHHO +DUG&RQYHQWLRQDO*ULQGLQJ:KHHO F%1:KHHO 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 Infeed Rate 0.005~0.03mm/pass 0.003~0.005mm/pass 0.002~0.003mm/pass Dress Out (Traverse cycles) 0～4times 0~4times 0~4times Feed Rate 80~140mm/min See below See below

Ŷ)HHG5DWH 'RZQ'UHVVLQJ 8S'UHVVLQJ Vr 3HULSKHUDOVSHHGUDWLR 9V V r (RD peripheral speed) =RD revolution (min-1) ×RD O.D.×π Vs (grinding wheel peripheral speed) =grinding wheel revolution (min-1) ×O.D.×π Operation C Standard 0.025~0.1 Efficient grinding High speed grinding 0.125~0.2 Feed rate = C × RD width × grinding wheel revolution Centerless grinding 0.005~0.01

28 Dresser Data Rotary Dressers

ƑTechnical Data In dressing, the surface roughness of grinding wheels is influenced by elements such as: 1. Peripheral speed ratio (Vr/Vs), 2. Infeed per revolution of wheel (Ar), and 3. dress out (Na).

1. Peripheral Speed Ratio 2. Infeed Rate ①Influence of Peripheral Speed Ratio on ①Influence of Infeed Rate of Grinding grinding Wheel Surface Roughness Wheel Surface Roughness Ɣ&RQWURORIWKHJULQGLQJVXUIDFHDFFXUDF\E\XS- Ɣ+LJKHUIHHGUDWHVFUHDWHDPRUHRSHQJULQGLQJVXU- dressing is easier than by down-dressing face (grinding ability increases) Ɣ+LJKHUIHHGUDWHFUHDWHVPRUHRSHQJULQGLQJVXUIDFH Ɣ/RQJHUGUHVVRXWWLPHGLPLQLVKHVVKDUSQHVVRIWKH (grinding ability increases) grinding surface

15 (Na=Dress out wheel rotation frequency)

10 Down Dress Na=0

10 8 m) μ m) (

μ 6 ( Up Dress Na=0

Down Dress Na=80 5 4 Down dress Up dress Up Dress Na=80 0 Surface Roughness of Grinding Wheel Grinding Surface of Roughness 1.5 1.0 0.5 0 -0.5 -1.0 -1.5 2 Surface Roughness of Grinding Wheel 0 0.18 0.36 0.54 0.72 Peripheral Speed Ratio (Vr/Vs) Infeed Rate (μm/rev) Test Conditions Grinding Wheel WA60K ②Influence of Infeed Rate on Dressing Force Rotary Dresser #20/30 Ɣ/DUJHUIHHGUDWHLQFUHDVHVQRUPDOIRUFH JULQGLQJ ability increases). Grinding Wheel Peripheral Speed Vs=29m/s Ɣ7DQJHQWLDOIRUFHVKRZVWKHVDPHWHQGHQF\DV Dress Out Na=0 normal force, but the value is much smaller. Infeed per rev.of grinding wheel

$U ȝPUHY 6 Vr 0.5 Down Dress =0.81 ȝPUHY -1 Vs 0.4 ȝPUHY 5,000min ȝPUHY 4 0.3 -1 Vr Down Dress =0.16 Vs 1,000min 0.2 ②Influence of Peripheral Speed Ratio on 2 Vr Up Dress =0.81 -1 Vs Dressing Force 5,000min 0.1 Normal Force (N/mm) Force Normal 0 (N/mm) Force Tangential Ɣ/DUJHUSHULSKHUDOVSHHGUDWLRDOORZVKLJKHUQRUPDOIRUFH 0 0.18 0.36 0.54 0.1 0.2 0.3 0.4 0.5 0.6 (increasing in grinding ability) Infeed Rate (μm/rev) Infeed Rate (μm/rev) Ɣ7DQJHQWLDOIRUFHVKRZVWKHVDPHWHQGHQF\DVQRUPDO force, but the value is much smaller 3. Dress Out 8 Influences of Dress out on Grinding Wheel 6 Surface Roughness Ɣ/RQJHUGUHVVRXWWLPHLQFUHDVHVURXQGQHVVRIWKH 4 grinding surface, but reduces sharpness.

2 Normal Force (N/mm) Force Normal 12 0 1.0 0.50 -0.5 -1.0 10 Peripheral Speed Ratio (Vr/Vs) 0.6 8

0.5 m)

μ 6 ( 0.4 4 Down Dress 0.3 Up Dress 2 0.2 Surface Roughness of Grinding WheelSurface of Roughness Tangential Force (N/mm)

0.1 0 1.0 0.5 0 80 150 240 320 Grinding Wheel Revolution During Dress Out (rev/sec) Peripheral Speed Ratio (Vr/Vs)

29 Rotary Dresser, Crown Dresser

Rotary Dresser for internal grinding machine Crown Dresser

Straight Type Features

Ŷ Dresser 1. &9'GLDPRQGSURYLGHKLJKZHDUSURRISHUIRUPDQFH like monocrystal diamond. &RQVWDQWDQGVWDEOHDFWLYHDUHDZLWKSULVPGLD- mond. &RVWHIIHFWLYHZLWKQRUHZRUNLQJ 4. Adjusting the diamond size and distribution enable to optimaze the dressing performance.

Straight Type Model Number S40-NS40-CS40-

6 120° 6 6 0.3R For Grinding

Profile +0.005 0 +0.005 0 +0.005 0 10 40 10 40 10 40

Diamond layer Disposition &9'3ULVP Inpregnated Diamond size 63& 0.4×0.4 SD#40 Concentration SFV&LUFXPIHUHQFH SFV&LUFXPIHUHQFH 3.3ct/cm3 Size &9'6L]H Pitch D Ø35~180 Cup Type 0.2Ƒ, 0.4Ƒ, + Ø 8~ 30 0.8~2mm 0.6Ƒ, 0.8Ƒ T 6~ 20

T D +

Model Number C40-N C40-C C40-

18 18 18 Cup Type

Profile +0.018 0 +0.018 0 +0.018 0 40 40 40 15 15 15

Diamond layer Disposition &9'3ULVP Inpregnated Diamond size 63& 0.4×0.4 SD#40 Concentration SFV&LUFXPIHUHQFH SFV&LUFXPIHUHQFH 3.3ct/cm3 Other sizes and spedicications available upon request Size &9'6L]H Pitch Straight Type Cup Type D Ø40~80 0.2Ƒ, 0.4Ƒ, Ø10~20 0.8~2mm + 0.6Ƒ, 0.8Ƒ T 15~20 *Other sizes and spedicications available upon request

D T

30 Dresser For Grinding Disc Dresser, CVD Ace Dresser

Diamond Disc Dresser CVD Ace Dresser

ŶFeatures ŶFeatures Adopted precise electro-deposition and surface form- 1. Adopted CVD diamond for high-wear-proof like ing technique to obtain high accurate tooth profile single crystal diamond forming 2. Prism diamond has fixed active area to maitain ŶApplication stable performance Tooth profile forming of gear grinding (mm) L L1 D W T Dressing for worm gear grinding wheel 50 38 11 10 9

* Please contact us for special sizes

L L1 ▽▽▽ D W

C O.5 Û 1.8 T 4

Û Û Gear Grinding

31 Cutting Tools

Diamond is superior to "hardness" and "theremal extensibility" as well as "sharp edge" created by polishing and that is the reason to be used as cutting tool material. Diamond cutting tools show ultra-precision, long tool life, high-efficiency and high precision cutting process through its features.

Tool edge comparison

Nano polycrystalline Diamond "SUMIDIA binderless"

Ŷ%/83& Single Crystal Diamond

Single Crystal Diamond

Diamond UPC PCD(Polycrystalline Diamond) Ŷ NewD Ŷ e-EDGE Surface roughness comparison for each diamond

Ultra Precision cutting tool (Single crystal diamond) Polycrystalline Diamond Nano polycrystalline diamond cutting tool Ɣ3&'5HDPHU

Ɣ3&'(QGPLOO Single crystal diamond cutting tool Ɣ3&'6PDOO6DZ

PCD (Polycrystalline diamond cutting tool)

0 0.05 0.1 0.5 1.0 5 XQLWȝP5D

32 Cutting Tools Single Crystal Diamond Ultra Precision Cutting Tools

Nano/Microforming Tools Ultra-Precision Cutting Tool UPC® 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 meet market needs. Our many years of experience and extensive knowledge give us a comprehensive understanding of the optimal physical properties of single 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 of workpieces in the order of nanometers.

ƑIdentification and Measurement Technology Anisotropy of the atomic distance Identify the anisotropy of atoms in single crystal diamond and pursue

the best crystal orientation a a a Creation of tools pursuing cutting edge sharpness in the order of nanometers starts with the screening a 2 a 2 and selection of single crystal diamond. 2 2 a a a The lattice constant of diamond is always 3.5667 Å, 2 2 but the distance between crystal faces varies, causing Diamond Lattice Model 2 a 12 1 a 2 a Diffraction image of differences in the ease of cleavage and intrusion of 4 4 3 a (100) plane impurities.Therefore, sorting of rough diamonds is im- 4 portant in addition to the identification of crystal orientation according to the machining conditions. (100) (110) (111)

ƑPolishing and Measurement Technologies Waviness 44.5nm

Cutting edge polishing technology that 250nm

produces nanometer-controlled movement 125nm

45° 45° ƍ 0 ƍ In order to accurately produce nanometer- 125nm 250nm controlled movement on a workpiece, a cut- SEM image of UPC-R cutting edge shape ting tool requires a sharp cutting edge capable of producing nanometer-sized chips and high profile precision. We have achieved this using our unique Manu. No. polishing and measurement technologies. :LQGRZ$QJOHƍ Corner Radius 0.052mm Corner Height 4.120mm 80nm 500nm Chart of inspection using Sharply-polished Nanometer-sized chips our originally-developed profile meter single crystal diamond cutting edge ƑNano/Micro Processing Technology Straightness and surface roughness unattain- 15μm-wide Nano endmill tip able with photolithography or ion-beam method

With its cutting edge sharpness in the order of nanometers, A.L.M.T.'s UPC-Nano series achieves a surface roughness and straightness that cannot be obtained by the photolithography or ion-beam method. This technology is also effective

for micrometer-order processing of ȝP high aspect ratio.

Polished surface shown in the same magnification Molds surface by microforming

33 BL-UPC

SUMIDIA Binderless (Nano-Polycrystalline Diamond) ƑSharp Cutting Edge Equivalent to Single Crystal Diamond

Ultra-Precision Cutting Tool / BL-UPC Cutting Tools

ȝP Nano-Polycrystalline Diamond

® ® Employs SUMIDIA Binderless on the edge of UPC ƑFlank Wear Comparison of Machined Carbide Achieves long tool life in mirror finish and fine machining of carbides

ŶFeatures of SUMIDIA® Binderless ƔFine grains of several tens of nanometers are firmly and directly bonded together without binder. 0.025mm ƔHarder than mono crystalline diamond. BL-UPC ƔNo anisotropy and specific cleavage. No Large Chipping Found ŶFeatures of BL-UPC ƔSuperior chipping and wear resistance compared to Wear single-/polycrystal diamond. Chip ƔSharp and precise cutting edge equivalent to UPC® (Single crystal diamond). ƔFree from uneven wear caused by crystal orientation 0.025mm due to no anisotropy. UPC® (Single Crystal Diamond) Large Chipping Found ŶApplications Molds for carbide glass lenses Large molds for prism sheets and light guide plates ƑComparison of Required Characteristics for Cutting Tool Materials Glass lenses Diamond Machining of other high-hardness and brittle materials Required Characteristics Single Polycrystalline Nano- Crystal polycrystalline

①High Hardness ◎ ◎ ◎ ②High Temperature Hardness ○ ○ ◎ Surface roughness of cemented carbide ③Suitable Toughness × △ ○ +12.44 ④High Thermal Diffusibility ◎ ○ ◎ ⑤Sharpness of Cutting Edge ◎ × ○ nm

-16.21 Surface Roughness Ra 5.4nm “SUMIDIA®” is a registered trademark of Sumitomo Electric Industries, Ltd.

34 Cutting Tools 6LQJOH&U\VWDO'LDPRQG UPC

For ultra fine grooving (QGPLOO 6TXDUHW\SH UPC®-Nano groove UPC®1DQRHQGPLOO

Cutting Edge Cutting Edge

ŶFeatures ŶFeatures 7KHZRUOG VVPDOOHVWJURRYLQJWRROZLWKDFXWWLQJ (QDEOHVWKHZRUOG VWKLQQHVWLQLWVFODVVȝPZLGH HGJHZLGWKRIȝP IOH[LEOHJURRYLQJ 3URYLGHVWKHZRUOG VKLJKHVWGLPHQVLRQDODFFXUDF\ (QDEOHVPDFKLQLQJZLWKDKLJKDVSHFWUDWLRRI RIȝP WLPHVWKHURWDWLRQGLDPHWHU +LJKSUHFLVLRQSROLVKHGGXUDEOHFXWWLQJHGJH +LJKSUHFLVLRQSROLVKHGGXUDEOHFXWWLQJHGJH (QDEOHVKLJKSUHFLVLRQILQHJURRYLQJWKDWFDQQRWEH (QDEOHVKLJKSUHFLVLRQILQHJURRYLQJWKDWFDQQRWEH DFKLHYHGXVLQJWKHSKRWROLWKRJUDSK\RULRQEHDP DFKLHYHGXVLQJWKHSKRWROLWKRJUDSK\RULRQEHDP PHWKRG PHWKRG

ŶApplications ŶApplications +RORJUDPGLIIUDFWLRQJUDWLQJPROGV +RORJUDPJUDWLQJ )LQHOLQHDUJURRYLQJ )LQHIUHHFXUYHJURRYLQJ 0ROGVZLWKILQHJURRYHV /&'OLJKWJXLGHSODWHPROGV 2SWLFDOVKHHWPROGV 0LFURPDFKLQHSDUWVJURRYLQJ

L/W ≦ 5 L

L 0.01 ± 0.0005 W ± A

L 45° 45° 。 Ø 1

0° 45 W 30’ ±

。。 0 B □W 30’ 0° □A （0.5）（1）

8.5 5 G 16

① L : 51 W : □6.35 ① L : 50 W : Ø6 6WDQGDUGVL]HV 6WDQGDUGVL]HV ② L : 60 W : □8 ② L : 30 W : Ø4

&XWWLQJHGJHRIQPZLGWK 3URFHVVH[DPSNHRI1DQRHQGPLOO

ȝP ȝP ȝP ȝP

35 UPC

(QGPLOO %DOOW\SH )RUPW\SH ® ® UPC 1DQREDOOHQGPLOO UPC -Nano Profile Cutting Tools

Cutting Edge Cutting Edge 6LQJOH&U\VWDO'LDPRQG

ŶFeatures ŶFeatures 7KHZRUOG VVPDOOHVWLQLWVFODVVEDOOHQGPLOOZLWK (QDEOHVIOH[LEOHRQHSDVVPDFKLQLQJRIIUHHIRUP 5 ȝP VXUIDFHVLQFOXGLQJHOOLSWLFDODQGSDUDERORLGDOVXUIDF 3URYLGHVWKHZRUOG VKLJKHVWSURILOHRIQP HVZLWKDIRUPDFFXUDF\RIȝPRUOHVV (QDEOHVKLJKSUHFLVLRQ'PDFKLQLQJZLWKLWVH[ (QVXUHVKLJKIRUPDFFXUDF\LQPDFKLQLQJRISDUDE WUHPHO\VKDUSFXWWLQJHGJH RORLGDODQGRWKHUIUHHIRUPVXUIDFHV

ŶApplications ŶApplications 0LFUROHQVDUUD\ 2SWLFDOVKHHWPROGVIRU/&'SDQHOV )UHHIRUPVXEPLOOLPHWHUOHQV 0LFUROHQVDUUD\PROGV /&'OLJKWJXLGHSODWHPROGV 9DULRXVRSWLFDOHOHPHQWPROGV 0LFURPDFKLQHSDUWVJURRYLQJ

L (OOLSWLFDO

0～0.005 ° W

° 30°

R 15 W.A

Displacement between radius center and Ø6 center is 0.005 max. PP

(OOLSWLFDOFXWWLQJHGJH 3DUDEROLFFXWWLQJHGJH （0.010） 5 15° G 20° 20

① L : 50 W : Ø6 6WDQGDUGVL]HV ② L : 30 W : Ø4

3URFHVVH[DPSOHRI1DQREDOOHQGPLOO

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45°

36 Cutting Tools Single Crystal Diamond UPC

UPC®-R

Infrared lens, UPC cutting edge for cemented carbide

UPC-R shows extraordinary success in ultra precision spherical and aspherical cutting applications. 1~3μm Negative rake face ŶFeatures Clearance $FKLHYHVDQHGJHDUFSURILOHRIQP ȝP over a wide working angle range of 90°. Uniform negative rake face on cutting edge (patent pending) 2. The cutting edge is uniformly finished in high quality, achieving a surface roughness in the order of nanometers. Close-up of L Cutting Edge 3. A record of the edge arc profile measured with our originally-developed measuring instrument (with a 40Û resolution of 5nm) is attached to the product for W

thorough quality control. 0.5

ŶApplications &RUQHU5DGLXVȝP W+0.5 1. Camera lens molds for CD, DVD, and BD players

2. Lens molds for digital cameras L : 51 W : 6.35 Standard Sizes ① □ 3. Camera lens molds for smartphones, PCs, and tab- ② L : 60 W : □8 lets 4. Infrared lens 5. Spherical and aspherical mirrors for lasers and X- ƑTool Nose Shape rays 6. Various spherical and aspherical lenses 7. Profile processing using a ultra-precision processing machine

ƑDimensions & Limit Precision Contour Corner Tool Edge Angle Tool Width Clearance Angle Rake Angle Type ș≦90° ș≦120° ș≦150° Radius R κ (RR) Į ȕ Ultraprecision ȝP ȝP ȝP 0.002 0.5 SS UPC-R ~ min 15° ~ 0°~20° -30°~10° Precision ȝP ȝP ȝP 200 5 S

37 Ƒ Plane andcylindricalmirrorfinishing 4. Photosensitive drumsofcopyingmachines 3. 2. Polygon mirrors Laser reflectivemirrors 1. Ŷ You2. canobtainuniform,high-qualityworkedsurfac- 1. Drastically reduces ordispenseswithrunning-in Ŷ Ƒ Exhibits its potential in high-efficiency ultra-precision ultra-precision high-efficiency in potential its Exhibits cutting into plane and cylindrical shapes cylindrical and plane into cutting UPC-FR UPC-FC Type UPC Dimension andHighest Accuracy Applications Features Cutting Edge cessing conditions. ting edgeaccordingtotheworkmaterialandpro- es bysettingtheroundness(sharpness)ofcut- processing time. P-CUPC-FR UPC-FC Tool Edge Angle Edge Tool 0~5 2.0~4.0 10°~45° 45°~80° ® ș FUPC -F Tool Width 1.0~4.0 W Clearance Angle Clearance 2°~5° 0°~5° Į Exclusive EdgeforPolygonMirrors Rake Angle -5°~0° R 0° ȕ Side Rake Angle 0°~15° 0° Ȗ

W 30 Rake Face ~ 40mm R 2. Guaranteesthecuttingedgeshapeinorderof 1. Thecuttingedgeisuniformandextremelysharp, Ŷ 5. Other finegrooving 5. Various4. diffraction gratingmolds Optical sheetmolds 3. Fresnel lensmolds 2. LCD lightguideplatemolds 1. Ŷ Fresnel lenses Ideal forfinegroovingsuchasthat Ƒ Ƒ UPC-T Features Applications Dimension andHighest Accuracy Cutting Edge submicrons. free fromchippingandundulation. Type Ultraprecision Precision SS S ® UPC-T -T Tool Edge Angle Edge Tool less 45° min 45° ș Tolerance ± Angle ± Molding of LCD display optical waveguide optical display LCD Molding of 15

6 ’ ’ Sharp Corner Sharp PLQȝP Leading Edge Width High-precision ±6 Standard ±15 Clearance Angle Clearance 0°~15° ’ Į ’ ȝP UPC Rake Angle -5°~10° ȕ

Cutting Tools Cutting Single Crystal Diamond Crystal Single Cutting Tools Single Crystal Diamond New D

New D Tools ƑPerformance of New D Tools Ɣ&RQGLWLRQV 'DWD Cutting Speed 565m/min Feed Rate 0.2mm/rev Depth of Cut 0.12mm Coolant Alcohol oil mist Work Material High-silicon aluminum alloy (Si:18％)

Data 1 Tool Life and Stability Comparisons (Interrupted Cutting) &XWWLQJ'LVWDQFH:KHQWKH)ODQN:HDU:LGWKLVȝP

(Km)

8 7 6 5 4 3 Cutting Distance 2 1 New D Tools Conventional

Data 2 Tool Life Comparison for Interrupted Cutting Tools ȝP 100 C,D:Conventional mono crystalline diamond tools 90 D Achieves stable and long tool life by mea- 80 C suring and optimizing the crystal orientation. 70 60 50 A,B:NewD Tools 40 ŶFeatures B Flank Wear Width Flank Wear 30 1. Less dispersion in tool life, which is a weakness of A 20 single crystal diamond tools, and 1.5 to 2 times lon- 10

ger tool life than conventional tools on average. 1 2 3 4 5 6 7 8Km 2. The combination of our originally-designed inserts 1.8 5.3 8.8 12.4 min Cutting Distance / Cutting Time and holders enables easy and precise tool setting like indexable inserts. Data 3 Recommended Range of Cutting Condition for New D Tools 3. There are inserts for straight cutting and those for (mm/rev) 0.2 curved-surface copying. The form accuracy of the Precision Cutting Area ODWWHULVȝP

4. The rake face is free from adhesions and accumu- 0.1 Mirror Cutting Area lation of chips and maintains the high quality of Feed Rate worked surfaces even during continuous use.

5. The diamond is firmly attached by a unique brazing 0.05 0.15 mm Depth of Cut method. 6. Exhibits high durability even during interrupted cutting. Ɣ([DPSOHRI&XWWLQJ 7. Unlike the conventional type with a retaining cap, there is no retaining cap to hold the diamond, en- abling chips to move smoothly on the rake face, im- proving the machining accuracy.

ŶApplications Automotive components (pistons, aluminum wheels, compressors, commuta- tors, etc.) Plastic lenses, resin parts HDD parts Aluminum die cast alloys, other non-ferrous metals

1) Curved-Surface Copying 2) Straight Cutting

39 New D, e-EDGE

ƑInsert Types (inventory items) Types Clearance I.C. I.H. Thickness

Corner Cutting Tools Insert Specifications Angle ØA ØB h Holder Long Life Type *1 Precision Type Radius (mm) (mm) (mm) When ordering NWD-CL302 NWD-CP302 R0.2 NWD - Chip CD NWD-CL305 NWD-CP305 R0.5 NWD-C L 3 02 Corner radius R0.2 NWD-CL308 NWD-CP308 R0.8 NDH-R1Ƒ Tool angle 55° I.C. Ø9.525 7° Clearance NWD-CL310 - R1.0 -L1 angle 7° Long life type (Precision type is “P”) Ƒ - R1.6 Ø4.4 +0.2 - NWD CL316 - Ø9.525 4-0 N1Ƒ R NWD-CL320 - R2.0 NDH-QR1Ƒ 55° NWD-PL302 NWD-PP302 R0.2 -QL1Ƒ A - - R0.5 㱵 NWD PL305 NWD PP305 NWD-PL308 NWD-PP308 R0.8

h 11° NWD-PL202 NWD-PP202 R0.2 NDH-ROƑ NWD-PL205 NWD-PP205 R0.5 +0.2 - Ø6.35 Ø2.8 3-0 LOƑ 㱵B NWD-PL208 NWD-PP208 R0.8 -NO Ƒ Single Crystal Diamond *2 For aluminum wheels NDH-R20V NWD-CL416 NWD-CL416-AW R1.6 -L20V +0.2 35° 7° Ø9.525 Ø4.4 R NWD-CL420 NWD-CL420-AW R2.0 5.5-0 -R25V A - - - - 㱵 NWD CL425 NWD CL425 AW R2.5 L25V *1 : Precision type/cutting edge contour precision 5um or less ƑHolder Types (inventory items) *2 : Special process to cutting edge Types Size (mm) Holder Specifications Insert Right Hand Left Hand WL S h L NDH-R06 NDH-L06 6 50 6.5 6 NWD-PP2 30° ƑƑ NDH-R08 NDH-L08 8 60 8.5 8 -PL2ƑƑ W

S - NDH-L10 10 80 10 10 - □ NDH R10 NWD CL3ƑƑ NDH-R12 NDH-L12 12 100 12 12 -PL3ƑƑ

95° h NDH-R16 NDH-L16 16 125 16 16 -CP3ƑƑ

▽ L NDH-QR10 NDH-QL10 10 80 13 10 -PP3 17°30 ƑƑ NDH-QR12 NDH-QL12 12 100 15 12 W

S NDH-QR16 NDH-QL16 16 125 19 16 □

▽ 30 107° L NDH-R20V NDH-L20V 20 150 25 20 NWD-CL416 45° NDH-R25V NDH-L25V 25 150 32 25 -CL420

W - □ S CL425

100° L Free 62° NDH-N06 6 50 - 6 NWD-PP2ƑƑ 30 ▽ NDH-N08 8 60 - 8 -PL2ƑƑ

W When ordering NDH-N10 10 80 - 10 NWD-CL3ƑƑ NDH - Holder CD □ -PL3ƑƑ ▽ NDH-N12 12 100 - 12 NDH-R 0 6 30 -CP3ƑƑ Ƒ6 62° NDH-N16 16 125 - 16 -PP3ƑƑ Right Hand (Left Hand is “L”) Please inquire for specifications except the above in the case of an order

NewD e-EDGE Patent granted To meet customer's demands for low cost and green operation, we introduce the NewD e-EDGE for multi-purpose single crystal cutting tool for aluminum.

ŶFeatures 1. Low cost / high performance 2. Special holder for HDD aluminum die cast part and internal cutting in stock 3. Special inserts for existing holders 4. Sharp cutting and very good cutting heat diffusibility (compared to poly crystalline diamond)

40 Cutting Tools Ultrasonic vibration cutting device / Single Crystal Diamond Ultrasonic vibration cutting system

Ultrasonic vibration cutting device Ŷ)HDWXUHVRI(/Ȉ (/Ȉ Product of Taga Electric Co.,Ltd. 1. High frequency around 41kHz makes 1ȝm or more elliptical vibration 2. Ultra precise tecnique of automatic tracking for elliptical vibration route with lower than 1nm precision 3. Small vibrator can be attached to ultra precision machine or machining center 4. Work with AC 100V and no need for special instal- lation work

ƑSpecifications outline 0DLQVSHFLILFDWLRQVRI(/Ȉ Frequency 41kHz ±1.5kHz ȝPSSaȝPSSYDULDEOH Oscillation of elliptical vibration Actual value of oscillation stability : 2nm or less Max. ultrasonic power 45Wmax Ultra precise diamond cutting of harden steel, cement- Main controller sizes W433×H140×L473 14Kg 1unit ed carbide and glass is possible with dedicated UPC Sizes of ultra precision bipolar amplifier W200×H261×L400 16Kg 2units Oscillation sizes W74×H50×L160 1Kg 1unit ŶFeatures of elliptical vibration cutting Applicable tools 83&IRU(/Ȉ 1. Mirror finish cutting of harden steel and stainless 2. Stable mirror finish cutting of cemented carbide and glass 3. High accurate corner cutting ƑProcess application for mirror finish of

Image of ultrasonic elliptical vibration cutting 83&IRU(/Ȉ harden steel(STAVAX 52HRC)

Chips

UPC 0.4 20° cutting edge 10°

Work material cross-section Ultrasonic elliptical vibration

ƑOuter drawing of vibrator Mirror finish of cemented carbide 67 36 54.5

28 46.5 43 16 105.5 mounting hole í 133.5 Ø5

36 11 Ultra precision cutting of optical glass Cable 5m ( 24 ) 15 56.4 33.4 8 ( 21.8 )

Ultrasonic vibration cutting device is jointly developed by Nagoya Univ. and Taga Electric Co.,Ltd.

41 PCD Reamer & Endmill PCD Rotating Tool Cutting Tools ŶFeatures 1. Multiple parts can be machined in a single pass by using an integrated formed step tool. 2. Adoption of diamond offers significantly-improved tool life (10 times or longer than that of carbide ones). 3. Excellent machining surface can be obtained even with cutting speeds at over 300m/min. 4. Stable cutting is possible even when using emulsion-type water-soluble coolant. (Semi-dry cutting is also possible according to your environment.) ƑApplication of PCD reamining (Reaming of automotice hydraulic regulator valves) 180 Item PCD Reamer Carbide Reamer 120 120

Ø16 Cutting Speed (m/min) Ø10 Feed Speed (mm/Rev) 0.2 0.2 Machining Allowance (mm/dia.) 0.4 0.4 (80) PCD 56 Coolant water-soluble oil-based

Ø10 Surface Roughness (μmRz) 3 8 Cirularity 5 10 workpiece Running Cost Ratio 0.5 1 ŶData 1 Improvement of Productivity by ŶData 2 Capable of both high-efficiency Breaking Chips and high-precision machining Negative Land Specification Cutting Edge The coaxiality and cylindricity of the cutting edge have greatly improved due to high shank rigidity (carbide) and grinding technology on cutting edge. The high run-out precision leads to stable machining, and consequently, reduction of the cycle time.

Valve Seat Hole

The breaker function is enhanced to prevent a reduction in productivity due to problems caused by chips. Solutions are Valve Guide Hole proposed according to the type of chip problem.

Diagram of work material Cross section of machining tool

ƔDifference of Performance Between Shank Materials Without chipbreaker Machining Results 1tooth 4teeth (steel) 4teeth (carbide) Machining time (s) 52 26 13 Circularity (mm) 0.01 0.05 0.03 Coaxiality (mm) 0.01 0.07 0.05 Ɣ0DFKLQLQJFRQGLWLRQV Split cutting chips Workpiece Cylinder head, valve seat, guide hole Material Aluminum alloy casting AC4B Machines Horizontal machining center

Chips curl thickly and split Tool Size Ø11-Ø36-L150 #of Rotations (min-1) 3500 Cutting Speed (m/min) 395 Feed Rate (mm/rev) 0.3

With chipbreaker Machining Allowance (mm/dia) 0.5 Coolant Emulsion type water-soluble

42 Cutting Tools PCD PCD Reamer & Endmill

ŶMachining Process

Process 1 Finishing of Valve-and-Sheet Fitting Holes Process 2 Finishing of Hydraulic Lash Adjuster (HLA) Holes Process 3 Finishing of Intake and Exhaust Valve Guide Holes

Process 1 Finishing of Valve-and-Sheet Fitting Holes

The high rigidity of the shank and accuracy of the cutting edge achieves coaxiality and cylindricity. Ŷ Specifications for Finishing of Valve-and-Sheet Fitting Holes Processing machine : Horizontal machining center Spindle Speed (min-1) 6,000 Cutting Feed Rate (mm/rev) 0.48 Conditions Feed Rate (mm/min) 2,880 Stock Removal (mm/dia.) 0.6 Coolant Emulsion-type water-soluble oil

Process 2 Finishing of Hydraulic Lash Adjuster (HLA) Holes

Optimized design for machining of thin-wall parts and stop holes improves chip removal and achieves a high cylindricity. Ŷ Specifications for Finishing of Hydraulic Lash Adjuster (HLA) Holes Processing machine : Horizontal machining center Spindle Speed (min-1) 5,000 Cutting Feed Rate (mm/rev) 0.34 Conditions Feed Rate (mm/min) 1,540 Stock Removal (mm/dia.) 0.5 Coolant Emulsion-type water-soluble oil

Process 3 Finishing of Intake and Exhaust Valve Guide Holes

Since the overhang (L) is long and the diameter (D) is small, consequently L/D is large, the coaxiality and cylindricity of tools are controlled with high accuracy to improve the self-guide effect during reaming. Additionally, chip evacuation is improved by the guide shape and coolant design. As a result, the tool life is increased to 10 times as long as that of carbide. Ŷ Finishing of Intake and Exhaust Valve Guide Holes Processing machine : Horizontal machining center Spindle Speed (min-1) 3,250 Feed Rate (mm/rev) 0.1 Cutting Feed Rate (mm/min) 325 Conditions Stock Removal (mm/dia.) 0.1 Coolant Emulsion-type water-soluble oil Machined Part Ŷ Results Material Tool Life（ No. of Holes） Price Ratio Cost Ratio Coaxiality Inner Diameter Variance Carbide 1,200 1 1 - - A.L.M.T. PCD Tool 12,000 3 0.8 ȝP ȝP000hole

43 PCD Reamer & Endmill Tools for cylinder head machining Cutting Tools ŶFeatures ŶAdvantages ƔOptimised tool balance for high-feed machining. ƔImprovement of the feed rate and machining quality. ƔEffective direction of internal coolant supply. Ɣ5HGXFWLRQRIWRROFRVWVSHUPDFKLQLQJ

PCD Reamers with multi-edge shapes. ŶFor Solenoid Hole Machining ŶFor Spark Plug Hole Machining PCD

ŶFor Guide-and-Sheet Hole Machining ŶFor Spring Sheet Hole Machining

PCD Reamers with high precision cutting edge and high rigidity of the shank. ŶFor Valve Guide Hole Machining ŶFor Lash Adjuster Hole Machining

PCD endmills that enables high-feed rate machining PCD endmills that enables high-feed rate machining using the high rigidity of the shank using the multi-edge structure ŶFor Camshaft Bearing (Half R) Machining ŶFor Cam Oil Hole Grooving

44 Cutting Tools PCD PCD Reamer & Endmill Special Tools for Automotive aluminum parts Machining ŶFeatures Ɣ7RROGHVLJQHGG\QDPLFEDODQFHIRUKLJKHUFXWWLQJVSHHG Ɣ5HGXFHWKHPDFKLQLQJWLPHDQGWKHWRROFRVWE\RXUVSHFLDOWRRODGDSWHGIRUKLJKIHHGLQWHJUDWHPDFKLQLQJSUR- cesses.

ŶAdvantages Ɣ,QWHJUDWLRQRISURFHVVHV6KRUWHUF\FOHWLPH Ɣ(OLPLQDWLRQRIYDULDQFHLQTXDOLW\GXHWRWRROVHWV Ɣ7RPLQLPL]HTXDOLW\YDULDWLRQGXHWRWRROVHWWLQJ

With a run-out adjustment function ŶMechanical Clamp Monoblock

Enables high-efficiency high-precision machining Enables higher feed machining using multi using the rigidity of the shank teeth set on the small body ŶMonoblock ŶFace Milling Cutter

Achieves high-efficiency machining by a structure that integrates several processes ŶSpecial Process Integrating Tools Reamer + Cutter Reamer + Tap

45 PCD Small saw

PCD Small Saw ŶProcess example

Ɣ:RUNPDWHULDO&RPSRXQGPDWHULDORIFRSSHUDQG Cutting Tools UHVLQ ØPPZLGWK 2XWHUJURRYLQJSURFHVV Ɣ0DFKLQH'HVLJQDWHGVOLFHU Ɣ6SHFLILFDWLRQØPPPP EODGHWKLFNQHVV QXPEHURIEODGH Ɣ&RQGLWLRQV&XWWLQJVSHHGPPPLQ '2&PP )HHGUDWHPPLQ PPEODGH Ɣ5HVXOW$FKLHYHGWLPHVWRROOLIHFRPSDUHGWRFRY- HQWLRQDOFXWWLQJWRRO Rotating Tool Ƒ(QODUJHGSLFWXUHRIHGJH

+LJKDFFXUDWHDQGHIILFLHQWFXWWLQJRUJURRYLQJSUR- FHVVIRUUHVLQDQGQRQIHUURXVPDWHULDOVDUHUHTXLUHG UHFHQWO\3&'6PDOO6DZZDVGHYHORSHGWRPHHWZLWK WKLVUHTXLUHPHQW

ŶFeatures Ɣ/RQJHUWRROOLIHFRPSDUHGWRFRQYHQWLRQDOWRROVGXH WRVXSHULRUZHDUUHVLVWDQFHRIFXWWWLQJHGJH Ɣ%HWWHUFXWWLQJHGJHDQGKLJKHUIHHGUDWHFRPSDUHGWR WKLQEODGH 'XHWRWKHUHDVRQDERYHIROORZLQJVDUHH[SHFWHG ,PSURYHVXUIDFHTXDOLW\ EXUUOHVVDQGEXULQLQJ LVQRWPXFK ,PSURYHSURGXFWLYLW\ 5HGXFHWRROFRVW

ŶPossible production range Ɣ2XWHUGLDØ20~76.2mm Ɣ%ODGHWKLFNQHVVaPP 6RPHH[FHSWLRQGHSHQGLQJRQWRROVSHFLILFDWLRQ

46 Diamond Wire Saw

Fixed Abrasive Diamond Wire Patent granted ŶPWS Features (PWS-R E) ® PWS Precision Wire Saw High-precision, high-efficiency (cutting speed:2 to 10 times the loose abrasive wire) Improved working environment (a water-soluble machining fluid can be used) Significantly improved material (separation and collection of the chips) Specifications can be selected accoridng to needs and applications

ŶApplications Brittle materials such as sapphire, glass, ceramics and quartz Magnetic material such as neodymium and ferrite magnets Silicon for semiconductors and solar cells More difficult to cut materials , SiC and various substrates ƑStandard specification for Fixed Abrasive Diamond Wire Saw formula Type Diameter Average Diamond Size Production Length PWS-R Ø0.255 ± 0.01 íȝP ~100km Ø0.250 ± 0.01 íȝP ~ 50km PWS-E Ø0.190 ± 0.01 íȝP ~ 50km *For longer products, and other specifications, please contact us Outline of Multi-wire Saw Workpiece Nozzle Nozzle

Main Roller Main Roller

47 PWS

PWS-R (Resin Bonded Type) PWS-E (Electroplated Type) Diamond

Wire

Saw PWS

PWS-R Type Surface PWS-E Type Surface ŶPWS-R Features ŶPWS-E Features High finishing quality of cut surface High cutting efficiency due to high diamond retention Ideal for slicing a variety of materials

ƑCase Processing Specifications : PWS PWS-R PWS-R PWS-E Evaluation System Multi-wire saw Multi-wire saw Multi-wire saw

Work Material Neodymium magnets Sapphire Sapphire Materials Dimension W(50×4columns)×H(25×4high)x×L(50×2columns)mm Ø50mm×L200mm Ø50mm×L200mm Wire Speed max 800m/min max 400m/min max 400m/min Work Feed Speed 0.6mm/min Ave 0.1mm/min Ave 0.3mm/min Cutting Wire Running Direction Reciprocate running Reciprocate running Reciprocate running Condition Wire Tension 35N 35N 35N Coolant Water-soluble Water-soluble Water-soluble Surface Roughness (Ra)* RQDQGOHVVWKDQȝP on and less than 0.4ȝP on and lesVWKDQȝP Waviness (WCM)* RQDQGOHVVWKDQȝP RQDQGOHVVWKDQȝP RQDQGOHVVWKDQȝP Cutting Total Thickness Variation (TTV) RQDQGOHVVWKDQȝP RQDQGOHVVWKDQȝP RQDQGOHVVWKDQȝP Results Average Wafer Thickness 0.74mm 0.6mm 0.6mm Kerf-loss 0.26mm 0.26mm 0.26mm

PWS Diamond Abrasive Size íȝP íȝP Specification Outer Diameter Ave. 0.250mm Ave. 0.250mm *Total length of cutting direction was measured.

Ɣ:RUNSLHFH6DSSKLUH ƔWorkpiece : Monocrystalline silic High Cut-through resistance Low Coolant ACoolant B Coolant C

Cutting resistance varies depending on the coolant. Please contact us for assistance in selecting the optimal coolant. Ý Ý Ý Ý

48 Other Machinery / Coolant CPG Series

For PCD Tool Grindig ŶOptions CPG Series Compact Tool Grinders Special power-up units for CPG Series

Suitable for super hard tool Grinding D.O.C. digital unit Ɣ&3* ŶFeatures Digital Display of D.O.C. by lin- 1. Incomparable rigidity ear scale (min.1ȝm) Diamond and cBN grinding require 10 times grinding Ɣ&3* pressure compared to cemented carbide grinding. Digital Display by combination of ball screw mechanism length measuring encoder (min.5ȝm) CPG series employ precise angler bearing for grinding spindle and pivot and frame itself is originally de- Turning angle digital Display &RRODQW7DQN Ɛ signed rigidly. Turning angle measuring Improved filtering system 2. Excellent grinding accuray encoder (min.1min.) with paper filter Super rigid and accurate grinding spindle realize sharp cutting edge. 3. High efficient operation Quick setting for cutting edge angle and relief angle with oscillating location adjustment of wheel with workpiece sight. Leaning mechanics with centering grinding point and highly precise projector for high efficiency operation environment. ŶAccessories Special jigs to guarantee grinding accuracy for CPG Series (genuine parts) *Painted color of grinder is image and CPG-310 standard color is green

ŶOptions Ɣ%UDNHWUXLQJXQLW%7 Ɣ'YLVH ƔØ250mm projector Ɣ$QJOHPHDVXUHPHQWSURMHFWRU Ɣ'2&GLJLWDOPHWHU Ɣ7XUQLQJDQJOHGLJLWDOPHWHU

Ŷ0DLQVSHFLILFDWLRQV ƔØ150mm projector ƔConstant pressure (grinding) unit Ɣ&RRODQWXQLW Ɣ+ROGHU 4& DQG7DEOH Ɣ5DSLGIRUZDUGEDFNZDUGXQLW Ɣ+ROGHUV High Operativity and High Output Ɣ2QPDFKLQHGUHVVLQJ unit CT-1 (CPG-310) Constant pressure unit is user friendly and helps to find suitable grinding condition. Oscillating width adjustment is operated easily by steering. X20 projector for centering and profiling. Ɣ-LJIRUF\OLQGULFDOJULQGLQJ

CPG-200 Basic grinding machine for low volume production Ɣ-LJIRUUDGLXVJULQGLQJ Ɣ-LJIRUHGJHKRQLQJ Adequate precision and rigidity as compact tool grinder X20 projector for centering and profiling

49 Equipments Grinding wheel profile forming unit Rotary Dresser drive unit Coolant ODIUP Other Machinery / Coolant ŶFeatures Features Water soluble grinding coolant specialized to reprace Ŷ from loose abrasive to fixed abrasive 1. High precision Employed high precision pivot adjusted run-out of outer and edge to less than 2μm ŶApplications PWS (Fixed) Diamond Wire 2. High rigidity DPG (Diamond Pellet Grinding) wheel Make spindle dia. as big as possible and employ angular bearing 3. Easy to use Ultra presicion dressing system Fix with T-slot to surface grinding machines No need to take out joint for removing TACUMINO Dress

ƑSpecifications of drive unit Spindle unit (SU type) is separately sold Spec Type SGS-30 SGS-50 SGS-100 Rotation speed (60Hz) 300rpm 2,500rpm 2,500rpm Electric motor 90W/200V 400W/200V 750W/200V Weight (kg) 22 55 67 Spindle SU-30 SU-50 SU-100 Dresser dia.and width (mm) Ø90×30 Ø150×50 Ø150×100

Truing Unit Brake Dresser

ŶFeatures World's smallest class High-speed rotation up to 20,000 Detect contact of wheel and dresser with submicron range

1. Decrease product defects drastically with high precision dressing AE censor system denefits accurate dressing 2. Reduce dressing time drastically AE censor system removes useless dressing 3. Increase tool life drastically ŶFeatures Increase number of dressing by reducing useless The brake dresser removes run-out with pressing dressing force between dresser and diamond wheel as well as [Selling agency] Sumitomo Electric Tool Net peripheral speed difference

50 Information &XVWRPHU6ROXWLRQ&HQWHU Customer Solution Center

,QWURGXFWLRQRI&XVWRPHU6ROXWLRQ&HQWHU &6& Propose most suitable condition of cutting / grinding process Customer Solution Center (CSC) proposes best solution for your problem by gathering know-how of DQDO\VLVHYDOXDWLRQDQGH[SHULHQFHWKDWKDYHFXOWLYDWHGRYHUWKH\HDUVDVDPDQXIDFWXUHU

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Meeting ering customer's request. Propose high precision and high efficiency cutting process that realizes space saving and clean environment. ƑFree abrasive to Grinding Select machining process through meeting 0DFKLQHWRRO :RUNKROGHU Plan 3) Process condition 7RROVSHFLILFDWLRQ

([SHULHQFHDFWLRQRI ZRUNPDWHULDOHTXLS- ment and tool during Propose high precision and high efficiency grinding process process evaluation. An- lead to low damage to work material under clean environment alyze work material Operation that realize improvement of working condition and washability and tool by measure- of work material as well as reducing industrial waste. ment and analytical in- strment after process. Ƒ0HDVXUHPHQWWRDQDO\VLVDQGHYDOXDWLRQ Propose most suitable process and tool for QH[WVWHSE\VXPPDUL]- LQJDQDO\VLVHYDOXD-

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51 Customer Solution Center

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Record chip status during cutting process by high speed camera. Load truing and dressing system on machine. Observe and Information Observe and analyze cutting status by tool dynamometer. analyze grinding status under various gridning condition.

0RWRUORDGDPSHUHPHWHU 0RWRUORDGDPSHUHPHWHU Revolution Indicator Cutting Tool Revolution Indicator Grinding Wheel Rotary Dresser

X +LJK6SHHG&DPHUD Y 9LEURPHWHU Z 6XUIDFHURXJKQHVVJDXJH Dressing Wheel &XVWRPHU6ROXWLRQ&HQWHU 7RROG\QDPRPHWHU ;<=IRUFHFRPSRQHQWV Brake Dress Y 7RROG\QDPRPHWHU Rotary Dresser drive unit X ;<=IRUFHFRPSRQHQWV Z

ƑPhoto by high speed camera Ƒ*ULQGLQJSURFHVVH[DPSOHRIHDFKVSHFLILFDWLRQ

:RUNDPRXQW ȝP ȝP Load current of main spindle (A) $

PLQ PLQ PLQ Specification SD8000V(A) SD8000V(B) SD8000V(C) Wafer status Polish Etching As sliced )HHGUDWH ȝPPLQ ȝPPLQ ȝPPLQ :RUNDPRXQW ȝP ȝP ȝP Load currentof main spindle $ $ $ Wear amount of grinding wheel ȝPZI ȝPZI ȝPZI

Analysis and evaluation ƔAnalysis of flatness and waviness : 3-D flat faFHDQDO\VLVXQLW7523(/ Ɣ6XUIDFHDQDO\VLV3-D surface analysis unit Zygo Measure and analyze wafer sur- 'DQG'VXUIDFHVWDWXVDUHRE- IDFHXSWRPP' tained by nondestructive inspection. 0HDVXUHPHQWDFFXUDF\P $QDO\VLVDELOLW\RIKHLJKWGLUHFWLRQQP 0HDVXUHPHQWUDQJH P 9HUWLFDOVFDQQLQJVSHHG PVHF

Ɣ2EVHUYDWLRQE\KLJKPDJXQLILFDWLRQDQGFRPSRQHQWDQDO\VLVEDX-SEM ƔCutting/Grinding resistance : 7RROG\QDPRPHWHU E\.LVWOHU Observe and analyze up to Process characteristic are PPIRUGLDPHWHUPP grasped by comparing 3 force VWUDLJKWW\SH DQGPP FXS components. type) for height.

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52 Information Safety Precautions Safety Precautions

Please read through user manual and inspection sheet of Diamond and cBN grinding wheel, PCD cutting tool, grinding machine and coolant before using for your safety. User manual needs to be kept in the distance that user can reach anytime. Accident or injury may be occured by misusage. The extent of danger and damage may be caused by misusage are categorized in 2 steps and stated below.

Warning : Misusage may cause death or seriouse injury Caution : Misusage may cause slight injury or physical damage

Prohibited matters Precautions Protective equipments are required

Safety precautions of Diamond and cBN wheels in use Ɣ Do not attach with force by hammering etc. Ɣ Do not operate to change inner dia 1. Work environment / Work clothes / Protective equipment Please instruct us if necessay Warning Ɣ 6FUHZIODQJH by equable torque at the position of diagonal Ɣ Wheel guard must be properly attached line Ɣ Only authorized people attend around machine and do not Ɣ Check overhang length does not surpass limitation stand at rotation direction Important notice Must wear dust-proof glasses, safety shoes, safety ◎ May balance on machine after being attached to the ma- hat and appropriate clothes chine Ÿ Caution ◎ May loose attachment of wheel and flange to screw by Ɣ Ventilate to remove mist coolant and dust checking run-out of reference face close to abrasive layer Must wear dust-proof mask and ear plug Ɣ Clean floor around grinding machine 4. Trial run Ɣ Instruct moving range of table of grinding machine etc. on Warning the floor Ɣ Check work material is firmly attached and operation of feed Ɣ Do not put anything or stand within its moving area mechanism work correctly Ɣ Do not operate in the area of inflammable object because Ɣ Check wheel is firmly attached and operation of feed mech- wheel sparks in use anism work correctly Ɣ Check rotation direction of wheel 2. Before use Ɣ Check irregular sound or vibration by no-load operation Caution around 1-3 mins Ɣ Check wheel sizes to match with requirement of grinding Caution machine Ɣ Check coolant is correcly supplied Ɣ Check apperance (crack, fracture, breakage etc.) after cleaning wheel 5. Grinding operation Ɣ Wash corrosion inhibitor in case wheel body is ferrous mate- Warning rial Ɣ Do not touch wheel when rotating Ɣ Clean wheel mouting portion of spindle Ɣ Make completed stop when irregular sound or vibration oc- Ɣ Clean flange and chuck to confirm no damage, warp and cuerd bend etc. Ɣ Turn off a switch only after stopping coolant supply Ɣ Check warp and bend on wheel Ɣ Do not touch or put object to stop rotating wheel Ɣ Read user manual and confirm wheel is for appropriate us- Ɣ Turn off a switch when wheel is taken out from spindle age Caution Ɣ Be careful of excess cutting especially dry tool cutting 3. Attachment Ɣ Confirm feed, D.O.C. and cycle time by trial run Warning Ɣ Check burning or chatter mark on work material Ɣ Turn off a switch when wheel is attached to spindle Ɣ Be careful of overload Ɣ Attach wheel gurad appropriately Caution 6. Storage and handling Ɣ Check scratch and dust etc. around or inside of mounting Caution portion of wheel, flange and chuck Ɣ Check crack, scratch, breakage, burning etc. on working Ɣ Remove small scratch etc. by sandpaper face Ɣ Hold wheel with enclosed cushion material to prevent crack Ɣ 6WRUHGU\DUHDDQGSUHYHQWGURSRIIDQGFUDVKHWF etc. in case of vitrified bond wheel Ɣ Apply corrosion inhibitor to ferrous wheel body to store Ɣ Wheel and flange need to be smoothly attached Ɣ Do not operate to change wheel shape. Please instruct us if

53 Safety Precautions

necessary mechanism work correctly Tool or work material breakage may occur injury Information Ɣ Check rotation direction of tool Safety precautions of Circular Saw in use It may occur injury if it is not correct Ɣ Check irregular sound or vibration by no-load operation 1. Work environment / Work clothes / Protective equipment around 1-3 mins Warning Ɣ Designated wheel guard must be properly attached 5. Cutting operation Otherwise, in case tool is broken, serious injury may occur Warning Ɣ Only authorized people attend around machine Ɣ Do not touch tool when rotating to remove risk of serious in- Do not approach to the area of rotation direction and mov- jury ing area of machine table Ɣ Make completed stop when irregular sound or vibration oc- Must wear dust-proof glasses, safety shoes, safety hat cured to remove risk of injury

and appropriate clothes Ɣ Cutting operation needs to be processed after reaching al- Safety Precautions 6OHHYHRUERWWRPRIFORWKHVQHHGWREHWLJKWQRWWRRFFXUVH- lowable rotation rious injury Ɣ Turn off a switch of main spindle after completion of cutting Must wear dust-proof mask and ear plug process Ɣ Do not operate in the area of inflammable object because Ɣ 'RQRWWRXFh or put object to stop rotating tool tool sparks in use Ɣ Turn off a switch when tool is taken out from main spindle Caution Caution Ɣ Ventilate to remove mist coolant and dust Ɣ Confirm feed, D.O.C. and cycle time by trial run Ɣ Clean floor around machine Ɣ Be careful of overload Ɣ Check burning or chatter mark on work material 2. Before use Important notice Warning ◎ Please consult us in case cutting condition or tool specifica- Ɣ Please use within peripheral speed stated tion is not correctly chosen Caution Ɣ Check tool sizes to match with requirement of the machine 6. Storage and handling Ɣ Remove edge protection and store it in the case Warning Ɣ Check crack and breakage etc. after washing corroision in- Ɣ Attach edge protection hibitor Touching directly to cutting edge may occur injury In case no irregular is confirmed, please attach edge protec- Ɣ ,PSDFWWRWRROPD\RFFur crack or breakage etc. tion Caution Protection removes risk of crack or injury of user Ɣ Check irregular wear, breakage, crack, peeling etc. on work- Ɣ Check warp and bend ing face Ɣ Clean mounting portion of main spindle Ɣ 6WRUHGU\DUHDDQGSUHYHQWGURSRIIDQGFUDVKDIWHUDQWL- Ɣ Chean flange and check scratch, warp, bend, irregular bal- corrision treatment and edge protection etc. ance etc. Ɣ 'RQRWRSHUDWHWRFKDQJHWRROVKDSH Please instruct us if necessary 3. Tool attachment Warning Ɣ Turn off a switch when tool is attached to main spind Safety precautions of PCD reamer and endmill Ɣ Check scratch and dust etc. around mounting portion of tool and apply sandpaper if necessary to remove Warning Ɣ Apply edge protection when tools is attached Ɣ Put safety cover and protection glasses etc. Ɣ Do not attach with force by hammering etc. Ɣ Do not touch sharp cutting edge by hand Ɣ Do not operate to change hole diameter Ɣ Check tool hand and rotation direction of machine Please instruct us if necessary Ɣ 6FUHZIODQJHE\HTXDEOHWRUTXHDWWKHSRVLWLRQRIGLDJRQDO line Ɣ Remove edge protection after attaching

4. Trial run Warning Ɣ Check tool is firmly attached and operation of feed mechanism work correctly Ɣ Check work material is firmly attached and operation of feed

54 Information Network Network

Network 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 production network (Diamond Tool) A.L.M.T. DIAMOND Corp. (Harima) Diamond cBN wheel, cutting tool / Rotary Dresser / Wear-resistance products A.L.M.T. DIAMOND Corp. (Shizuoka) Domestic production network (Functional Material) Diamond Tools Awaji Diamond Industrial Co.,Ltd. (Sumoto) A.L.M.T. TECH Inc. (Sakata) Diamond drawing dies / Heatspreader products / Tungsten Wear-resistance products Molybdenum products A.L.M.T. TECH Inc. (Toyama) Tungsten Molybdenum powder, stick, plate A.L.M.T. TECH Inc. (Itami) Electric Contacts,Heavy metal, Heatspreader products,Ceramic products A.L.M.T. TUNGSTEN Corp. (Toyama) Powderly products / Cemented carbide

Domestic Sales Network ŶHead Office 1-11-11, Shiba, Minato-ku, Tokyo, 105-0014 TEL : +81-3-5418-1809 FAX : +81-3-5418-1811

ƔTohoku Office ƔAtsugi Office Ɣ0LNDZDDQMR2IILFH ƔHokuriku Office ƔHiroshima Office Ɣ.LWDNDQWR2IILFH ƔNagoya Office ƔHamamatsu Office ƔOsaka Office Ɣ.\XVKX2IILFH

Other catalogues ŶFor semiconductor ŶFor drawing wire Diamond tool catalogues are available for various markets

Tyrolit ULTRA series (conventional wheel) ŶAutomotive bearing ŶGear (general), ŶGear (honing), ŶTurbine (general), ŶTurbine (viper grinding), CSS ULTRA MIRA ULTRA MIRA STRATO ULTRA VIPER ULTRA

55 Information Network

Network Global Network Information Technical & Reliable Network for A.L.M.T.Corp.

Domestic production network (Diamond Tool) A.L.M.T. DIAMOND Corp. (Harima) Diamond • cBN wheel, cutting tool / Network Rotary Dresser / Wear-resistance products

A.L.M.T. DIAMOND Corp. (Shizuoka) (Diamond Tool) : Sales : Production, Sales Domestic production network (Functional Material) Global Network □ ○ Diamond Tools □ Sumitomo Electric Hardmetal Trading (Shanghai) Co.,Ltd. Awaji Diamond Industrial Co.,Ltd. (Sumoto) A.L.M.T. TECH Inc. (Sakata) □ Sumitomo Electric Carbide, Inc. (Chicago)...... (Sales of Diamond tools) ...... (Sales of Diamond tools) 1001. Business Center Drive, Mt. Prospect, IL 60056-2181, U.S.A. Room J, 6/F Huamin Empire Plaza, No.728 Yan An Road(W), Diamond drawing dies / Heatspreader products / Tungsten • Tel: +1-847-635-0044 Fax: +1-847-635-9335 Shanghai, 200050, China Wear-resistance products Molybdenum products □ Sumitomo Electric Carbide, Inc. (Detroit) ...... (Sales of Diamond tools) Tel: +86-21-6212-9271 Fax: +86-21-6212-9272 A.L.M.T. TECH Inc. (Toyama) 14496 Sheldon Road, Suite 230, Plymouth, MI 48170, U.S.A. □ Sumitomo Electric Hardmetal Trading (Shanghai) Co.,Ltd. (Guangzou) Tungsten • Molybdenum powder, stick, plate Tel: +1-734-451-0200 Fax: +1-734-451-5338 ...... (Sales of Diamond tools) □ Sumitomo Electric Carbide, Inc. (Cincinnati)..... (Sales of Diamond tools) Room 21, A22F, China Shine Plaza, No.3-15 Lin He Xi Road, A.L.M.T. TECH Inc. (Itami) 4450 Carver Woods Drive, Cincinnati, OH 45242-5545, U.S.A. Tian He District,Guangzhou, 510610, China Electric Contacts,Heavy metal, Tel: +1-513-891-4000 Fax: +1-513-794-2911 Tel: +86-20-3881-5582 Fax: +86-20-3891-0904 Heatspreader products,Ceramic products □ Sumitomo Electric Carbide, Inc. (Huntsville)..... (Sales of Diamond tools) □ Taiwan Hong-yu Precision Tools ...... (Sales of Diamond tools) 6700 Odyssey Drive, Huntsville, AL 35806, U.S.A. 13 FA3., No.156, Sec.1, Zhongshan Rd., Banqiao Dist., A.L.M.T. TUNGSTEN Corp. (Toyama) Tel: +1-256-971-1203 Fax: +1-256-971-1205 New Taipei City 220, Taiwan Powderly products / Cemented carbide □ Sumitomo Electric Carbide, Inc. (Torrance)...... (Sales of Diamond tools) Tel: +886-2-29596721 Fax: +886-2-29596720 21241 S.Western Avenue Suite 200 Torrance, CA 90501, U.S.A. □ A.L.M.T. Asia Pacific Pte. Ltd. (Singapore) Tel: +1-800-950-5202 Fax: +1-310-782-0211 ...... (Sales of Diamond Tools and Diamond drawing dies) No.2 Boon Leat Terrace #03-02/03 Harbourside 2 Singapore 119844 Domestic Sales Network □ Sumitomo Electric Hardmetal de Mexico, S.A. de C.V. (Mexico) Tel: +65-6271-9252 Fax: +65-6274-2915 ...... (Sales of Diamond Tools) A.L.M.T. Asia Pacific Pte. Ltd. (Malaysia) Head Office □ ■ Av. Aguascalientes Sur 2625, Fracc. Jardines de las Fuentes, A-3-1 Mines Waterfront Business Park No.3, Jalan Tasik, The Mines 1-11-11, Shiba, Minato-ku, Tokyo, 105-0014 TEL : +81-3-5418-1809 FAX : +81-3-5418-1811 Aguascalientes, AGS., 20290, Mexico Resort City, 43300 Seri Kembangan, Selangor Darul Ehsan Malaysia ●Tohoku Office ●Atsugi Office ●Mikawa-anjo Office ●Hokuriku Office ●Hiroshima Office Tel：+52-449-993-2740 Fax：+52-449-993-2753 Tel: +60-3-8945-1090~1 Fax: +60-3-8945-1092 ●Kita-kanto Office ●Nagoya Office ●Hamamatsu Office ●Osaka Office ●Kyushu Office ○ A.L.M.T. (Thailand) Co.,Ltd. (Thailand • Wellgrow) □ Sumitomo Electric Hardmetal do Brasil Ltda..... (Sales of Diamond tools) ...... (Manufactur of Diamond Tools) Rua Maestro Agide Azzoni 67, Chácara da Barra, Campinas, 90/2 Moo 9 Wellgrow Industrial Estate Bangna-trad Road., 13090-724, SP, Brasil T.Bangwua A.Bangpakong Chachoengsao 24180 Thailand ■For semiconductor ■For drawing wire Other catalogues Tel: +55-19-3254-9494 Fax: +55-19-3254-4432 Tel: +66-38-522291~5 Fax: +66-38-522290 ○ A.L.M.T. (Thailand) Co.,Ltd. (Thailand • Korat) Diamond tool catalogues are available for various markets □ Sumitomo Electric Hartmetall GmbH (Germany • Dusseldorf) ...... (Manufactur of Diamond drawing dies) ...... (Sales of Diamond tools) Mooban Bannaklang 567 Moo 1 T.Naklang A.Soongnuen Konrad-Zuse-Strasse 9, D-47877 Willich, Germany Nakhonratchasima 30380 Thailand Tel: +49-2154-4992-0 Fax: +49-2154-4992-163 Tel: +66-44-335190 Fax: +66-44-335300 □ A.L.M.T. (Thailand) Co.,Ltd. (Thailand • Bangkok) ○ A.L.M.T. Henan Whirlwind Diamond Wheel Co.,Ltd. (China • Henan) ...... (Sales of Diamond Tools and Diamond drawing dies) ...... (Manufacture and sales of Diamond wheels) 54 B.B Building 15th Floor Room 1511 Sukhumvit 21 (Asoke), North 200 Renmin Road, Changge City, Henan Province China 461500 Klongtoey Wattana, Bangkok 10110 Thailand Tel: +86-374-6108758 Fax: +86-374-6108859 Tel: +66-2-2612231~2 Fax: +66-2-2612230 ○ A.L.M.T.Diamond Dies (SUZHOU) Co.,Ltd. (China • Suzhou) □ PT. Sumitomo Electric Hardmetal Indonesia (Indonesia) Tyrolit ULTRA series (conventional wheel) ...... (Manufacture and sales of Diamond drawing dies) ...... (Sales of Diamond tools) ■Automotive • bearing ■Gear (general), ■Gear (honing), ■Turbine (general), ■Turbine (viper grinding), Unit 25D,25E of Suchun Industrial Square, #428 Xinglong Street 88 Office Kota Kasablanka Tower A 11th floor Unit D CSS ULTRA MIRA ULTRA MIRA STRATO ULTRA VIPER ULTRA Suzhou Industrial Park, Jiangsu, P.R. China 215021 J1. Casablanca Raya Kav. 88, Jakarta Selatan 12870, Indonesia Tel: +86-512-62836195~7 Fax: +86-512-62836176 Tel: +62-21-2956-8508 Fax: +62-21-2956-8509

Global Network (Functional Material) □ : Sales ○ : Production, Sales □ Sumitomo Electric U.S.A.,INC. (Los Angels) ○ Chengdu Lianhong Molybdenum Co.,Ltd (Chengdu) ..(Manufactur of Tungsten, Molybdenum, Heatspreader products) ...... (Manufacture and sales of Molybdenum products) 21241 South Western Avenue, Suite 120 Torrance, CA 90501, U.S.A. No.198. Nanjing Road,Chengdu Economic & Technological Tel: +1-310-782-0227 Fax: +1-310-782-0211 Development Zone, Longquanyi District, Chengdu, China 610100 Tel: +86-28-88432450 Fax: +86-28-88432456

55 56 Diamon d • cBN Tools A.L.M.T.

• http://www.allied-material.co.jp/ Diamond cBN Tools Head Office 1-11-11, Shiba, Minato-ku, Tokyo, 105-0014, JAPAN TEL +81-3-5418-1809 FAX +81-3-5418-1811