Precision Engineering: Lapping in Industries

In today's manufacturing industry, precision is everything. With increased competition and a demand for ever-higher quality products, manufacturers are turning to cutting-edge technologies to improve their processes and products. One such technology is precision flat lapping, which involves using abrasive particles to polish and refine materials to extremely high tolerances.

One of the key benefits of precision flat lapping is its ability to work with a wide range of materials. At our company, we are able to process a variety of materials, including metals, ceramics, and semiconductors. This versatility allows us to work with customers across a range of industries, from aerospace and defence to medical devices and electronics. Advantage of precision flat lapping is its ability to achieve extremely high levels of precision. With our state-of-the-art equipment and experienced technicians, we are able to achieve flatness and parallelism to within millionths of an inch, making it possible to produce parts with exceptional accuracy and consistency.

We are proud to have assisted a wide range of industries in improving their processes with the use of precision flat lapping technology. Our expertise in this field has allowed us to provide tailored solutions that meet the unique needs of each industry we serve. Some of the industries we have had the privilege of working with include aerospace, defence, medical devices, electronics, and many more. We are dedicated to helping our customers achieve the highest levels of quality and precision in their manufacturing processes, and we look forward to continuing to make a positive impact on these industries and beyond.

Oil, Gas, Petrochemical, & Power Generation

Chemical Processing

The chemical processing industry requires lapping services to recondition various mechanical seal types for flow control equipment and pumps. These seals can be made of various materials such as silicon carbide, tungsten carbide, and carbon. Lapping systems are used to repair and recondition these seals, which can save time and money compared to replacing them. The lapping process involves removing a small amount of material from the surface of the seal using an abrasive slurry, resulting in a precise and smooth surface finish.

Cutter Manufacturing

In the cutter manufacturing industry, lapping services are used to sharpen and recondition slitting cutters. These cutters can be made of tungsten carbide or hard steel, with a thickness of only 1.6mm, making them difficult to grind. Slitting cutters are used for cutting plastic film and foil in packaging and printing applications. Lapping systems are also used to sharpen cutter blades for paper envelopes. The lapping process involves removing a small amount of material from the cutting edge using an abrasive slurry, resulting in a precise and sharp cutting edge.

Electronics

The electronics industry requires lapping services for various applications, including lapping and polishing computer disk drive GMR heads, recording heads, lamination stacks, ceramic substrates, ferrites, transducers, glass to metal seals, detonators, and trimmers. These components require a high level of precision and surface finish to function effectively. Lapping systems are used to achieve the necessary surface finish and dimensions required for these components. The associated industries for these applications include research, defence, computers, mobile phones, television, and aerospace.

Food Processing

In the food processing industry, lapping services are used for the reconditioning of mechanical seals in sugar refineries, among other applications. Systems up to 700mm diameter are utilised for lapping and polishing canning dies, where a high degree of flatness is required with a good quality surface finish. Lapping also helps produce sharp edges on cutting rings associated with these dies.

General Engineering

In general engineering, lapping services are utilised to produce flat datum faces on components or products. These components may be irregular in shape and challenging to grind, making lapping an ideal option. Templates, jigs, gauges, and castings are currently lapped using Kemet Lapping Systems in this industry.

Jewelry

The jewelry industry often uses Kemet Systems to lap and polish products made from brass, such as belt buckles, pen clips, cuff links, and identifying logos. Lapping and polishing using Kemet Lapping and Polishing Systems produces good cosmetic surfaces that provide an excellent base for any subsequent gold plating operation.

Measuring Equipment

Measuring equipment relies on precision and accuracy, making lapping and polishing services essential. Micrometre spindles and anvils, gauge blocks, toolmaker flats, and microscope stages are just a few examples of equipment that require good quality flat polished surfaces. Lapping and polishing processes ensure that these surfaces are smooth, even, and free of any imperfections, leading to more precise measurements.

Medical Devices

The manufacture of medical devices requires the highest level of precision and safety. Breathing apparatus is one such device that needs good quality flat surfaces on various parts where light pressure sealing is essential. Brass and stainless steel are commonly used in these devices, and lapping systems provide the necessary surface finishes to ensure proper function.

Racecar Industry

In the racecar industry, lapping services are used to polish and refine components with metal to metal sealing faces, ensuring their optimal performance. Commonly lapped components include diesel injectors, water pump parts, and small ceramic type seal faces. Lapping and polishing processes are particularly critical in this industry since any imperfections in the sealing faces can compromise the engine's performance and safety. By using lapping services, racecar manufacturers can achieve precise and accurate sealing surfaces that guarantee optimal performance and safety.

Pneumatic Equipment Industry

The pneumatic equipment industry utilises metal to metal seal faces in various components, such as compressors and flow control devices. Lapping services are used extensively in this industry to refine these seal faces and ensure their optimal performance. Brass and stainless steel seal faces are common in this industry, and lapping services are used to improve their flatness and surface quality. Kemet Iron Lapping Systems are used to produce acceptable seal faces on hard steel and tungsten carbide spray gun nozzles. By using lapping services, pneumatic equipment manufacturers can achieve precise and accurate sealing surfaces, ensuring optimal equipment performance and safety.

Power Generation

Power generation is a critical industry that requires high-quality components to ensure reliable and efficient operations. Both nuclear and conventional power stations use lapping systems to recondition and produce flat sealing faces on components. These components include valves, pumps, and flow control equipment.

Pump Seals Manufacture

Pumps are used extensively in various industries to move liquids, including chemicals, oils, and water. Companies involved in the manufacture and reconditioning of pumps use lapping systems to produce flat seal faces on mechanical seals and flow control equipment.

Shoulder Lapping

Toolmaking

Toolmaking involves the production of tools used in various manufacturing processes, including press tool dies, moulds, and cutting tools. In toolmaking, lapping is used to produce sharp cutting edges and precise surfaces that ensure accurate and consistent manufacturing processes. Kemet Lapping Systems are particularly valuable in toolmaking, especially for moldmakers who require precise and flat surfaces. Kemet's lapping systems can effectively lap press tool dies to produce sharp cutting edges that can withstand the high-stress conditions of manufacturing processes.