Industry Specific Lapping Services - Materials & Application
Maintenance departments in this industry use systems for reconditioning various mechanical seal types relating to flow control equipment and pumps.
Systems are used by a number of companies for lapping slitting cutters, these can be tungsten carbide or hard steel and cannot be ground due to their thin section, often 1.6mm thick. They are used for cutting plastic film and foil. Systems are also used for sharpening cutter blades for paper envelopes.
Applications include lapping and polishing computer disk drive GMR heads, recording heads, lamination stacks, ceramic substrates, ferrites, transducers, glass to metal seals, detonators, trimmers The associated industries are Research, Defence, Computers, Mobile Phones, Television and Aerospace.
Food processing applications are varied, with primary food manufacturers such as sugar refineries using systems for the reconditioning of mechanical seals in their maintenance department. In other areas, such as the canning industry, systems up to 700mm diameter are used for lapping and polishing canning dies where a high degree of flatness is called for with a good quality surface finish. The cutting rings associated with these dies are also lapped to produce sharp edges.
These applications are normally related to components or products that require a flat datum face from which to work. It is often easier to lap items that are irregular in shape than grind them, where work holding would become a problem. Components such as templates, jigs, gauges and castings are currently lapped using Kemet Lapping Systems in this industry.
Many jewellery products are lapped and polished using Kemet Systems, the most common applications are when brass is used as the base material. This is often the case for belt buckles, pen clips, cuff links and identifying logos. Lapping and polishing using Kemet Lapping and Polishing Systems produces good cosmetic surfaces which are an excellent base for any subsequent gold plating operation.
Successful applications in this industry include the lapping and polishing of micrometer spindles and anvils, gauge blocks, toolmakers flats, microscope stages and anywhere that requires a good quality flat polished surface.
Manufacturers of breathing apparatus use systems for producing good quality flat surfaces on various parts where light pressure sealing is essential. These parts are often of brass and stainless steel.
The use of Kemet Lapping Systems is now an accepted method for reconditioning mechanical seals in this industry. These can vary from the softer seals such as carbon through to the harder tungsten carbide and ceramic facings used in pumps, to the large gate valves in stainless steel used on offshore Oil Rigs.
Components lapped in this industry are those which have metal to metal sealing faces. In particular systems are successfully used for lapping/polishing diesel injectors, water pumps parts and numerous small ceramic type seal faces.
Pumps are used for many purposes, in particular the movements of liquid. Companies involved in the manufacture and reconditioning of pumps use systems for producing flat seal faces on mechanical seals and flow control equipment.
Gear faces and aerospace fuel and hydraulic systems will typically need very good flatness and surface finish on faces that have integral shafts. The shafts make it impossible to present the faces needing lapping to a normal lapping plate. Kemet have developed automated systems to overcome this challenge, replacing hand finishing techniques that are both time consuming and variable.
Kemet are able to process these types of parts in our sub contract facility generating flatness of less than 0.0005mm. (0.5 micron).
If you are looking for this type of service, simply send a drawing of the part needing processing along with quantities, and we will calculate exactly what is needed and issue a quotation which will include a bespoke annular groove plate and an optical flat specifically for your part.
For more details, complete the contact form below, and a technician will get back to you within 24 hours.
Manufacturers of mechanical seals use Kemet Lapping Systems extensively. The most common materials processed are tungsten carbide, stellite, ceramic, silicon carbide, carbon and brass. Seal rings up to 12” diameter are successfully lapped under production conditions to have mirror surfaces with flatness to 2 or 3LB.
Process Development & Free Material Testing
We regularly assist customers by developing new products and processes, utilising the very latest in precision flat lapping technology. Customers' samples are evaluated, free-of-charge. Comprehensive reports are issued covering all aspects of the process, including details of abrasive, lapping plate, workholding, inspection, cleaning and the likely consumable costs involved.
We are able process the following materials
Mould insert or cavity
Silicon Aluminium Alloy
Ultrasonic Cleaning Trials
Zirconate (Lead) Titanate
If a material does not appear in the list, please fill in the enquiry form or contact Kemet on +44(0)1622 755287
All processed samples are returned with detailed technical process reports including detailed surface finishing measurements, free of charge
Photo credits: Hardness Blocks, Laser Mirrors, Medical Device, Orthapaedics, Oil & Gas, Pump Valves, Factory