Polishing and lapping technology. System brochure

Polishing and lapping technology System brochure

9 9. Polishing and lapping technology // 9.1. Polishing and lapping machines and accessories Polishing and lapping machines joke EL Table-top machines Polishing and lapping machines joke EL Our Series EL polishing and lapping machines have been a byword for quality and reliability in professional use for many years. Both bench-top units EL 300 and EL 380 were developed especially for machining small workpieces and individual parts in small series production. For example, these units have been successfully used in laboratories and research institutions for many years. The EL 300 machines can be fitted with an application arm or a pendulum arm. A pneumatic application fixture and a bottom cabinet are available as accessories for the EL 380 machine. The large production machines EL 600 and EL 700 were designed for series production. These machines already offer stepless speed control as standard. In addition for example, pneumatic application fixtures and other components allow you to make adjustments to exactly suit the individual application. Optional pendulum arm system: Pendulum arm with com- Processing of concave Processing of dies i joke EL - also available for special cases! The series EL machines can also be modified for special applications, for processing of concave or convex surfaces for instance. Please consult Stefan Spiegel about the versatile possibilities: Tel. +49 (0) 22 04 / 8 39-0 s.spiegel@joke.de pensation mechanism geometries (convex) and lifting device Table-top machines EL 300 EL 380 Lapping disk Ø Ø 300 mm / 12 Ø 380 mm / 15 Lapping disk speed 20-200 1/min 60 1/min Number of roller yokes max. 3 (available as accessory) 3 (in scope of delivery) Dressing ring Ø, internal Ø 108 mm Ø 140 mm Volume lapping medium waste tank 6 l (in scope of delivery) 6 l (in scope of delivery) Drive motor power 0.2 kw 0.55 kw Supply voltage 230 V, 50/60 Hz 400 V, 50/60 Hz Fuse 16 A, slow-blow 16 A, slow-blow Connected load 0.5 kva 1.2 kva Dimensions (W x H x D) 500 x 300 x 600 mm 725 x 400 x 620 mm Weight 65 kg 150 kg Order No. 3 635 020 3 635 021 Price 2

9. Polishing and lapping technology // 9.1. Polishing and lapping machines and accessories 9 Polishing and lapping machines joke EL Production machines Pneumatic application fixture Spray unit Lapping (and polishing) disks Dosing unit Control electronics integrated into the housing Model EL 600 Spray arm / linear feed unit Production machines Lapping disk Ø Lapping disk speed Number of roller yokes Dressing ring Ø, internal Volume lapping medium waste tank Drive motor power Supply voltage Fuse Connected load Dimensions (W x H x D) Weight Order No. Price EL 600 Ø 610 mm / 24 30-60 1/min 3 (in scope of delivery) Ø 248 mm 12 l (in scope of delivery) 2.2 kw 400 V, 50/60 Hz 16 A, slow-blow 3.7 kva 1,300 x 1,375 x 1,160 mm 720 kg 3 635 221 EL 700 Ø 700 mm / 28 30-60 1/min 3 (in scope of delivery) Ø 275 mm 12 l (in scope of delivery) 2.2 kw 400 V, 50/60 Hz 16 A, slow-blow 3.7 kva 1,300 x 1,375 x 1,160 mm 720 kg 3 635 421 3

9 9. Polishing and lapping technology // 9.1. Polishing and lapping machines and accessories Accessory for polishing and lapping machines Application fixtures Hand weights polishing cloth disks Application fixtures and hand weights The pressure required for the working can optionally be generated with application fixtures or by using hand or loading weights. Application fixtures Order No. Price Manual application fixtures 1 application plate Application via spring force Height-adjustable Manual application fixture for EL 300 3 627 070 max. lapping pressure 10 kg (100 N) Weight 5 kg Pneumatic application fixtures Including application plates, Number of cylinders: 3, Can be individually switched and pressurised, Including loading weights Pneumatic application fixture for EL 380 32 003 622 max. lapping pressure 2.5 bar = 30 kg (300 N) Weight 50 kg Pneumatic application fixture for EL 600 32 005 004 max. lapping pressure 4 bar = 90 kg (900 N) Weight 140 kg Pneumatic application fixture for EL 380 32 005 005 max. lapping pressure 4 bar = 90 kg (900 N) Weight 140 kg Hand weights Dimensions Weight for model Order No. Price The hand weights are made of cast iron. They are used as an alternative to the pneumatic application fixtures. Ø 107 mm 1.9 kg EL 300 32 010 850 Ø 139 mm 3.3 kg EL 380 3 635 108 Ø 247 mm 11 kg EL 600 3 635 308 Ø 274 mm 13.5 kg EL 700 3 635 508 4

9. Polishing and lapping technology // 9.1. Polishing and lapping machines and accessories 9 Accessory for polishing and lapping machines Cast iron dressing rings Retaining and compensation disks Dressing rings Dressing rings mainly fulfil three functions: Holding workpieces being machined Supporting lapping medium distribution Keeping the lapping disk level via appropriate positioning Cast iron dressing rings Design Dimensions for model Order No. Price slotted Ø 143/108 x 35 mm 300 mm / 12 3 637 301 Ø 178/140 x 45 mm 380 mm / 15 3 637 303 Ø 286/248 x 70 mm 600 mm / 24 3 637 304 Ø 314/275 x 70 mm 700 mm / 28 3 637 305 Ø 457/408 x 102 mm 1.000 mm 3 637 311 Ø 545/480 x 102 mm 1.200 mm 3 637 312 Dressing rings made from stainless steel on request! Aluminium polishing cloth carrier disks Dimensions for model Order No. Price Polishing operations are normally performed on polishing cloths. To achieve this, these special carrier disks are used instead of the standard lapping disks. Ø 300 mm / 12 EL 300 3 630 052 Ø 380 mm / 15 EL 380 3 630 501 Ø 610 mm / 24 EL 600 3 630 502 Ø 700 mm / 28 EL 700 3 630 503 FAS disks with non-stick coating Dimensions Order No. Price These disks are glued to aluminium polishing cloth carrier disks. Their non-stick coating allows the user to easily replace self-adhesive polishing cloths. Ø 300 mm / 12 3 630 510 Ø 380 mm / 15 3 630 511 Ø 610 mm / 24 3 630 512 Ø 700 mm / 28 3 630 513 Workpiece holder Dimensions for model Order No. Price Workpiece holder made of hard paper for reliably guiding the workpieces. Ø 107 x 3 mm EL 300 3 635 112 Ø 139 x 3 mm EL 380 3 635 110 Ø 247 x 5 mm EL 600 3 635 309 Ø 274 x 5 mm EL 700 3 635 509 Compensating disks Dimensions for model Order No. Price Soft, adaptable rubber material for compensating any thickness tolerances in the workpieces. Ø 107 x 6 mm EL 300 3 635 105 Ø 139 x 6 mm EL 380 3 635 107 Ø 247 x 10 mm EL 600 3 635 302 Ø 274 x 10 mm EL 700 3 635 502 5

9 9. Polishing and lapping technology // 9.1. Polishing and lapping machines and accessories Accessory for polishing and lapping machines Lapping medium dosing units Spray units Lapping medium dosing units and spray units These dosing units are used to regulate the infeed of lapping medium during work. The spray units are used to ensure even application of the diamond suspension. With larger disk diameters, the manual feed unit is also used to achieve even distribution of the suspension. Lapping medium dosing units Order No. Price Pump with integrated agitator, Lapping agent dosing unit for EL 300 32 019 030 lapping medium tank Lapping agent tank volume 6 litres and cycle control. Pump motor power 0,08 kw Lapping agent dosing unit for EL 380 3 635 150 Lapping agent tank volume Pump motor power 6 litres 0,08 kw Lapping agent dosing unit for EL 600 / EL 700 3 635 350 Lapping agent tank volume Pump motor power 12 litres 0,08 kw Holder for lapping agent dosing unit for EL 600 and EL 700 32 004 344 not neccessary for machines with pneumatic application fixture Spray units and accessories Order No. Price Spray unit LAM PLAN 809 B 3 645 810-2 with built-in agitator for diamond suspension, 2 time switches for spray and breaking times, automatic and manual operation, container volume 0.5 litres Glass container for spray unit 3 645 812 Spray arm with 2 spray nozzles for 809 B 3 645 814-1 Spray unit LAM PLAN 909 3 645 817 complete with spray arm Glass container for spray unit 3 645 812 Spray arm with 3 spray nozzles for 909 3 645 818 Linear forward feed unit for EL 600 / EL 700 3 635 736 Stroke 125 mm, incl. spray arm and control 6

9. Polishing and lapping technology // 9.2. Polishing and lapping 9 Polishing and lapping Basics High gloss with exact accuracy of form Polishing and lapping is used when there are very exacting demands placed on surfaces with regard to peak-to-valley height and flatness, with a high gloss finish being required at the same time. These results are achieved in a single work cycle with polishing and lapping. Most preliminary and subsequent work steps are no longer required, and the entire working process becomes noticeably more rational. The results can be examined immediately thanks to the reflective surface. Our polishing and lapping system consists of three components: Schematic representation of the polishing and lapping process Polishing and lapping disk Dosing and spray unit Bio-diamond emulsions LAM PLAN NEOLAP The polishing and lapping system can be used successfully on almost all materials. This involves using the polishing and lapping disks in conjunction with the Bio-diamond emulsions LAM PLAN NEOLAP. The dosing and spray unit carries the lapping medium at precisely defined intervals to the lapping disk in the correct consistency and in the optimum quantity. This optimum dosing reduces consumption costs to a minimum. Worn polishing and lapping disks can be re-lined by us at any time. Knee implant The diamond suspension can also be custom adapted on request. Simply tell us your special needs and we will make the right product for you at short notice and for a reasonable price. So that we can give you the best possible advice right from the outset, we will carry out sample work for you at our application centre. We will then put together the optimum solution for you and your particular application. Sliding annular seal Inkjet nozzle Coining dies 7

9 9. Polishing and lapping technology // 9.2. Polishing and lapping Polishing and lapping disks LAM PLAN M.M. Bi-Composite Polishing and lapping disks LAM PLAN M.M. Bi-Composite The new LAM PLAN M.M. Bi-Composite polishing and lapping disc consist of two different materials in a resin bond. Water-soluble and oil-soluble diamond fluids are used as lapping media. The diamond grit is subjected to a constant change in speed by the polishing and lapping disk segments of different hardness. This results in high stock removal and a polished surfaced in only one single processing stage! In plain language this means: you process your workpieces using these polishing and lapping disks taking markedly less time and in fewer processing stages. This is not the only advantage. The flatness of the lapping and polishing disk is also distinctly improved thanks to the dualcomponent technology and is guaranteed for considerably longer. All disks can also be re-lined at our works. Polishing and lapping disks LAM PLAN M.M. Bi-Composite Dimensions Order No. Price Coarse preliminary Blue coarse processing, 15 45 µ abrasive Ø 300 mm / 12 3 644 030 work Ø 380 mm / 15 3 644 038 Ø 610 mm / 24 3 644 061 Ø 700 mm 3 644 070 Ø 914 mm / 36 3 644 091 Ø 1.000 mm 3 644 093 Ø 1.200 mm 3 644 095 Green fine processing, 3 15 µ abrasive Ø 300 mm / 12 3 644 130 Ø 380 mm / 15 3 644 138 Ø 610 mm / 24 3 644 161 Ø 700 mm 3 644 170 Ø 914 mm / 36 3 644 191 Ø 1.000 mm 3 644 193 Ø 1.200 mm 3 644 195 Yellow final processing, 1 6 µ abrasive Ø 300 mm / 12 3 644 430 Ø 380 mm / 15 3 644 438 Ø 610 mm / 24 3 644 461 Ø 700 mm 3 644 470 Ø 914 mm / 36 3 644 491 fine Finishing Ø 1.000 mm 3 644 493 Ø 1.200 mm 3 644 495 8

9. Polishing and lapping technology // 9.2. Polishing and lapping 9 Diamond dressing system LAM PLAN Diabloc Diamond dressing system LAM PLAN Diabloc For dressing the polishing and lapping disks. The system consists of a spherically lapped carrier disk made of aluminium, to which a self-adhesive plastic film coated with diamond pellets can be glued. The diamond pellets are available in various different grit sizes for the corresponding polishing and lapping disks. Aluminium carrier disks for diamond dressing system for disk dimensions Dimensions Order No. Price Ø 300 mm / 12 Ø 145 mm 3 645 720 Ø 380 mm / 15 Ø 178 mm 3 645 721 Ø 610 mm / 24 Ø 286 mm 3 645 722 Ø 700 mm / 28 Ø 315 mm 3 645 723 Ø 914 mm / 36 Ø 419 mm 3 645 724 Ø 1.000 mm / 40 Ø 457 mm 3 645 725 Ø 1.200 mm / 46 Ø 545 mm 3 645 726 Diamond pellets for recoating for disk dimensions Dimensions Order No. Price coarse Ø 300 mm Ø 145 mm 3 645 743 for polishing and lapping disks blue Ø 380 mm Ø 178 mm 3 645 744 Ø 610 mm Ø 286 mm 3 645 745 Ø 700 mm Ø 315 mm 3 645 746 Ø 914 mm Ø 419 mm 3 645 747 Ø 1.000 mm Ø 451 mm 3 645 748 Ø 1.200 mm Ø 545 mm 3 645 749 fine Ø 300 mm Ø 145 mm 3 645 736 for polishing and lapping disks green + yellow Ø 380 mm Ø 178 mm 3 645 737 Ø 610 mm Ø 286 mm 3 645 738 Ø 700 mm Ø 315 mm 3 645 739 Ø 914 mm Ø 419 mm 3 645 740 Ø 1.000 mm Ø 451 mm 3 645 741 Ø 1.200 mm Ø 545 mm 3 645 742 9

9 9. Polishing and lapping technology // 9.2. Polishing and lapping Ceramic dressing rings with SPYLAP control system Ceramic dressing rings with SPYLAP control system The patented SPYLAP control system allows highly simple control over the temperature of the lapping disk (and the resulting flatness) during dressing. Each ceramic dressing ring is equipped with SPYLAP elements which change in colour from black to red in response to temperature increase during processing. Changes can therefore be detected at an early stage and the process parameters such as press, diamond fluid, etc. can be adapted in order to reduce the temperature again, thereby ensuring preservation of lapping disk flatness. TEMPERATURE TOO MUCH MECHANICAL DEFORMATION SPYLAP ALERT LEVEL LAPPING TIME Ceramic dressing rings with SPYLAP control system for disk dimensions Internal dimensions Order No. Price Ø 300 mm / 12 Ø 107 mm 3 637 341 Ø 380 mm / 15 Ø 140 mm 3 637 342 Ø 610 mm / 24 Ø 248 mm 3 637 343 Ø 700 mm / 28 Ø 275 mm 3 637 344 Ø 914 mm / 36 Ø 368 mm 3 637 345 Ø 1.000 mm / 40 Ø 406 mm 3 637 346 Ø 1.200 mm / 48 Ø 480 mm 3 637 347 Cast iron dressing rings on page 5, rings made from stainless steel on request! Workpiece holder Dimensions for model Order No. Price Workpiece holder made of hard paper Ø 107 x 3 mm EL 300 3 635 112 for safely guiding the workpieces Ø 139 x 3 mm EL 380 3 635 110 Ø 247 x 5 mm EL 600 3 635 309 Ø 274 x 5 mm EL 700 3 635 509 Compensation disks Dimensions for model Order No. Price Soft, adaptable rubber material for compensating any thickness tolerances of the workpieces Ø 107 x 6 mm EL 300 3 635 105 Ø 139 x 6 mm EL 380 3 635 107 Ø 247 x 10 mm EL 600 3 635 302 Ø 274 x 10 mm EL 700 3 635 502 10

9. Polishing and lapping technology // 9.2. Polishing and lapping 9 Bi-composite polishing and lapping tools LAM PLAN M.M. Bi-composite polishing and lapping tools The bi-composite round rods and plates let you produce your own polishing and lapping tools. A A Use during reworking of valve seats, concave and convex surfaces, etc., etc. A A The three versions M.M. 980 (coarse), M.M. 991 (fine) and M.M. 992 (super fine) are used with the series 130 and 140 BioDIA- MANT diamond sticks (see page 16). B B C C C B Bi-composite polishing and lapping tools Dimensions Coating Type Order No. Price Round rods Ø 50 x 50 mm - MM 980 (coarse) 3 646 110 - MM 991 (fine) 3 646 111 - MM 992 (super fine) 3 646 112 Ø 75 x 50 mm - MM 980 (coarse) 3 646 210 - MM 991 (fine) 3 646 211 - MM 992 (super fine) 3 646 212 Plates Ø 50 x 15 mm 5 mm MM 980 (coarse) 3 646 310 5 mm MM 991 (fine) 3 646 311 5 mm MM 992 (super fine) 3 646 312 Ø 100 x 15 mm 5 mm MM 980 (coarse) 3 646 320 5 mm MM 991 (fine) 3 646 321 5 mm MM 992 (super fine) 3 646 322 Ø 150 x 15 mm 5 mm MM 980 (coarse) 3 646 330 5 mm MM 991 (fine) 3 646 331 5 mm MM 992 (super fine) 3 646 332 Ø 200 x 15 mm 5 mm MM 980 (coarse) 3 646 340 5 mm MM 991 (fine) 3 646 341 5 mm MM 992 (super fine) 3 646 342 11

9 9. Polishing and lapping technology // 9.2. Polishing and lapping Bio-diamond emulsions LAM PLAN NEOLAP Bio-diamond emulsions LAM PLAN NEOLAP Couldn t be greener and couldn t be better either. The brand new NEOLAP series from LAM PLAN is the new reference when it comes to performance, efficiency and userfriendliness. The products are biodegradable and VOC-free and can therefore be used without harm to humans and/or the environment. The emulsions achieve first-rate results on almost any material. They can also be used under conditions with very high contact pressure without any risk of running and the lubricant film tearing. The products are available in oil-soluble (series 100) and water-soluble (series 300) versions. The likewise water-soluble series 400 contains polycrystalline diamonds. These have a greater specific surface owing to their structure (multiple cutting) and provide high stock removal rates. This allows shorter processing times with simultaneous freedom from scratches! Inno-Check Very high stock removal performance for first-rate results Biodegradable and VOC-free Also usable under the most difficult production conditions Water-soluble and oil-soluble versions for all applications Selection of the matching polishing and lapping disks, emulsions and fluids according to material Material Polishing and lapping disks Diamond emulsion Fluid Roughness depth Ra Ceramic 1 NEOLAP 312 0,45 1 2 2 NEOLAP 303 0,1-0,3 Carbide metal 1 NEOLAP 325 0,1 1 2 2 NEOLAP 312 0,02 Silicon carbide 1 NEOLAP 325 0,15 1 2 2 NEOLAP 309 0,05 Stellite 1 NEOLAP 312 0,06 1 2 2 NEOLAP 306 0,02 Tempered steel 1 NEOLAP 325 0,15 1 2 2 NEOLAP 309 0,015 3 3 NEOLAP 306 0,008 Cast iron 1 NEOLAP 325 0,25 1 2 2 NEOLAP 312 0,06 Bronze 2 1 NEOLAP 309 0,04 Carbon 1 1 2 2 Stainless steel 1 1 2 2 Tempered stainless steel Ferrite 1 2 1 1 2 NEOLAP 306 NEOLAP 306 NEOLAP 312 NEOLAP 309 NEOLAP 312 NEOLAP 309 0,15 0,10 0,12 0,035 0,06 0,03 1 NEOLAP 306 0,09 Untempered steel 1 1 2 2 3 3 NEOLAP 315 NEOLAP 312 NEOLAP 306 0,15 0,06 0,03 12

9. Polishing and lapping technology // 9.2. Polishing and lapping 9 Bio-diamond emulsions LAM PLAN NEOLAP Bio-diamond emulsions LAM PLAN NEOLAP Type Grit size Contents Order No. Price Contents Order No. Price Series 100 oil-soluble Coarse 125 25 µm 400 ml 3 655 125 2 litres 3 655 125-1 Monocrystalline diamonds preliminary work 115 15 µm 400 ml 3 655 115 2 litres 3 655 115-1 fine Finishing 112 12 µm 400 ml 3 655 112 2 litres 3 655 112-1 109 9 µm 400 ml 3 655 109 2 litres 3 655 109-1 106 6 µm 400 ml 3 655 106 2 litres 3 655 106-1 103 3 µm 400 ml 3 655 103 2 litres 3 655 103-1 102 2 µm 400 ml 3 655 102 2 litres 3 655 102-1 101 1 µm 400 ml 3 655 101 2 litres 3 655 101-1 195 0,75 µm 400 ml 3 655 195 2 litres 3 655 195-1 Series 300 water-soluble Coarse 325 25 µm 400 ml 3 655 325 2 litres 3 655 325-1 Monocrystalline diamonds preliminary work 315 15 µm 400 ml 3 655 315 2 litres 3 655 315-1 fine Finishing 312 12 µm 400 ml 3 655 312 2 litres 3 655 312-1 309 9 µm 400 ml 3 655 309 2 litres 3 655 309-1 306 6 µm 400 ml 3 655 306 2 litres 3 655 306-1 303 3 µm 400 ml 3 655 303 2 litres 3 655 303-1 302 2 µm 400 ml 3 655 302 2 litres 3 655 302-1 301 1 µm 400 ml 3 655 301 2 litres 3 655 301-1 395 0,75 µm 400 ml 3 655 395 2 litres 3 655 395-1 Series 400 water-soluble Coarse 425 25 µm 400 ml 3 655 425 2 litres 3 655 425-1 Polycrystalline diamonds preliminary work 415 15 µm 400 ml 3 655 415 2 litres 3 655 415-1 fine Finishing 412 12 µm 400 ml 3 655 412 2 litres 3 655 412-1 409 9 µm 400 ml 3 655 409 2 litres 3 655 409-1 406 6 µm 400 ml 3 655 406 2 litres 3 655 406-1 403 3 µm 400 ml 3 655 403 2 litres 3 655 403-1 402 2 µm 400 ml 3 655 402 2 litres 3 655 402-1 401 1 µm 400 ml 3 655 401 2 litres 3 655 401-1 495 0,75 µm 400 ml 3 655 495 2 litres 3 655 495-1 Matching fluid (oil-soluble and water-soluble) Contents Order No. Price 1 litre 3 655 201 2 litres 3 655 202 5 litres 3 655 205 13

9 9. Polishing and lapping technology // 9.2. Polishing and lapping Polishing cloths LAM PLAN Polyester silk Polishing cloths High gloss surfaces can be achieved rapidly and reliably using our polishing cloths in combination with LAM PLAN NEOLAP diamond emulsions (see page 12/13). We supply you cloths for use on the widest range of materials and for different applications. Cloths with different properties are used depending on the desired result: soft cloths for a perfect high gloss in case of slight edge rounding or hard cloths for perfect edge sharpness. Consult our lapping expert Stefan Spiegel to find the ideal polishing cloth for your application: Tel. +49 (0) 22 04 / 8 39-0 Mail s.spiegel@joke.de Polyester polishing cloths LAM PLAN 9415 Taffeta, rigid carrier For preliminary processing, high stock removal Application examples: Semi-finishing of tantalum, TA6V, zirconium and soft materials Can be used with diamond fluid 6 25 µm, oil-soluble and water-based. Dimensions Type Version Packaging unit Order No, Ø 300 mm / 12 9415 self-adhesive 10 pieces 3 681 811 Ø 380 mm / 15 9415 self-adhesive 10 pieces 3 681 812 Ø 610 mm / 24 9415 self-adhesive 10 pieces 3 681 813 Ø 700 mm / 28 9415 self-adhesive 10 pieces 3 681 814 Ø 914 mm / 36 9415 self-adhesive 10 pieces 3 681 815 Ø 1.000 mm / 40 9415 self-adhesive 10 pieces 3 681 816 Price Silk polishing cloths LAM PLAN 9450 Silk fabric, flexible carrier For final polishing, low stock removal Application examples: Final polishing for all materials Can be used with diamond fluid 1 6 µm, oil-soluble and water-based. Dimensions Type Version Packaging unit Order No, Ø 300 mm / 12 9450 self-adhesive 10 pieces 3 681 509-1 Ø 380 mm / 15 9450 self-adhesive 10 pieces 3 681 510-1 Ø 610 mm / 24 9450 self-adhesive 10 pieces 3 681 511-1 Ø 700 mm / 28 9450 self-adhesive 10 pieces 3 681 512-1 Ø 914 mm / 36 9450 self-adhesive 10 pieces 3 681 513-1 Ø 1.000 mm / 40 9450 self-adhesive 10 pieces 3 681 514-1 Price 14

9. Polishing and lapping technology // 9.2. Polishing and lapping 9 Polishing cloths LAM PLAN Flocked (standard, soft, super soft) Flocked polishing cloths, standard LAM PLAN 9432 Flocked, flexible carrier Super finish, very low stock removal Application examples: Super finish of hard and moderately hard materials Can be used with diamond fluid 1/10 3 µm, also with aluminium oxide or colloidal silicon dioxide, water-based. Dimensions Type Version Packaging unit Order No, Ø 300 mm / 12 9432 self-adhesive 10 pieces 3 681 831 Ø 380 mm / 15 9432 self-adhesive 10 pieces 3 681 832 Ø 610 mm / 24 9432 self-adhesive 10 pieces 3 681 833 Ø 700 mm / 28 9432 self-adhesive 10 pieces 3 681 834 Ø 914 mm / 36 9432 self-adhesive 10 pieces 3 681 835 Ø 1.000 mm / 40 9432 self-adhesive 10 pieces 3 681 836 Price Flocked polishing cloths, soft LAM PLAN 9437 Flocked, flexible carrier Super finish, very low stock removal Application examples: Super finish of moderately hard and soft materials Can be used with diamond fluid 1 6 µm, water-based. Dimensions Type Version Packaging unit Order No, Ø 300 mm / 12 9437 self-adhesive 10 pieces 3 681 851 Ø 380 mm / 15 9437 self-adhesive 10 pieces 3 681 852 Ø 610 mm / 24 9437 self-adhesive 10 pieces 3 681 853 Ø 700 mm / 28 9437 self-adhesive 10 pieces 3 681 854 Ø 914 mm / 36 9437 self-adhesive 10 pieces 3 681 855 Ø 1.000 mm / 40 9437 self-adhesive 10 pieces 3 681 856 Price Flocked polishing cloths, super soft LAM PLAN 9431 Flocked, semi-flexible carrier Super finish, very low stock removal Application examples: Super finish of soft and very soft materials Can be used with diamond fluid 1/10 1 µm, also with aluminium oxide or colloidal silicon dioxide, water-based Dimensions Type Version Packaging unit Order No, Ø 300 mm / 12 9431 self-adhesive 10 pieces 3 681 871 Ø 380 mm / 15 9431 self-adhesive 10 pieces 3 681 872 Ø 610 mm / 24 9431 self-adhesive 10 pieces 3 681 873 Ø 700 mm / 28 9431 self-adhesive 10 pieces 3 681 871 Ø 914 mm / 36 9431 self-adhesive 10 pieces 3 681 875 Ø 1.000 mm / 40 9431 self-adhesive 10 pieces 3 681 876 Price 15

9 9. Polishing and lapping technology // 9.2. Polishing and lapping Manual polishing and lapping disks LAM PLAN Lamblock Diamond sticks Bio DIAMANT Manual polishing and lapping disks and Diamond sticks These disks are ideal for finishing on site or also for use in small series production. For example, they are suitable for polishing and lapping seals made of carbon, hard alloy, ceramic, silicon carbide or other materials. The disks (Ø 300 mm) are available in coarse, fine and super fine versions. Components with a solid surface of up to Ø40 mm and rings up to Ø70 mm can be processed. Also available: the Tri-Blocs case. This contains three disks (Ø140 mm) for preliminary to final polishing in three workings stages. It can be used to process components of up to Ø40 mm. Manual polishing and lapping disks with sticks Design Dimensions Diamond stick / Fluid Order No. Price blue - coarse Ø 300 mm / 12 Stick MM 131 + Fluid MM 712 3 645 655 green - fine Ø 300 mm / 12 Stick MM 141 + Fluid MM 712 3 645 654 yellow - super fine Ø 300 mm / 12 Stick MM 142 + Fluid MM 712 3 645 653 Tri-Blocs case Design Dimensions Diamond stick / Fluid Order No. Price 3 disks (coarse, fine, super fine) Ø 140 mm each 3 Sticks + Fluid MM 712 3 645 656 Diamond sticks LAM PLAN Bio DIA- Type Content Order No. Price Die Diamantsticks werden von Hand auf die Läppscheiben aufgetragen. Der Dosierstift Serie 130 - Coarse working MM 131 10 g 3 645 689 ist mit MM 132 10 g 3 645 688 MM 134 10 g 3 645 687 Serie 140 - Finishing MM 141 10 g 3 645 684 MM 142 10 g 3 645 683 MM 143 10 g 3 645 682 MM 144 10 g 3 645 681 MM 145 10 g 3 645 680 16

9. Polishing and lapping technology // 9.3. Lapping 9 Lapping Basics Systematic Lapping is a metalworking process for improving the dimensions, shape and roughness of spherical or flat workpiece surfaces. Loose grit is used for lapping. Here, the lapping process itself involves metalworking with loose grit, which is distributed in a liquid or compound. This involves pressing the individual grit tips into the surface. The material is carried off in all directions, which produces the matt surfaces that are typical of lapping. Schematic representation of the lapping process The lapping process primarily enables two requirements to be fulfilled on the workpiece: High to very high surface qualities Extremely high accuracies of form Optimum adaptation of the three basic components is a prerequisite for achieving these requirements: The workpiece being worked Abrasive in the carrier liquid Lapping disk as the shaping element Sliding annular seal Magnetic winding Microphone diaphragm Type wheel Sliding seal Gas seal 17

9 9. Polishing and lapping technology // 9.3. Lapping Cast iron lapping disks Cast iron lapping disks Together with the lapping agent, the lapping disk forms the lapping tool. Cast iron disks have proved to be advantageous in practice and guarantee optimum precision, flatness and surface quality when working. Cast iron lapping disks Design Dimensions for model Order No. Price slotted Ø 300 mm / 12 EL 300 3 637 001 Ø 380 mm / 15 EL 380 3 637 003 Ø 610 mm / 24 EL 600 3 637 004 Ø 700 mm / 28 EL 700 3 637 005 not-slotted cast iron lapping disks on request! 18

9. Polishing and lapping technology // 9.3. Lapping 9 Firm grit disks Firm grit disks for flat honing The firm grit disks and rings consist of a resin-bound silicon carbide mixture. They are available in various grit sizes. Water is sufficient as a lubricant. For optimum results, dressing rings of the same grit size should also always be used in this process. Areas of use: Composite materials Glass Reinforced plastics Work in which minimum contamination is essential. Firm grit disks Dimensions Grit size for model Order No. Price Ø 300 / 84 x 24 mm SIC 400 EL 300 3 637 521 SIC 1200 EL 300 3 637 522 Ø 380 / 100 x 24 mm SIC 400 EL 380 3 637 523 SIC 600 EL 380 3 637 533 SIC 1200 EL 380 3 637 524 Ø 610 / 113 x 27 mm SIC 400 EL 600 3 637 525 SIC 1200 EL 600 3 637 526 Re-Lining of firm grit disks on request! suitable dressing rings Dimensions Grit size Order No. Price Ø 143 / 108 x 55 mm SIC 400 3 637 541 SIC 1200 3 637 542 Ø 178 / 140 x 55 mm SIC 400 3 637 543 SIC 600 3 637 553 SIC 1200 3 637 544 Ø 286 / 248 x 90 mm SIC 400 3 637 545 SIC 1200 3 637 546 accessory Order No. Price Water connection with flexible intake and nozzle 3 630 058 Optional for operating the lapping machine without dosing unit or pump system 19

9 9. Polishing and lapping technology // 9.3. Lapping Lapping medium BIOLAM ready to use Lapping medium BIOLAM ready to use This ready-to-use lapping fluid is very easy to handle, provides an extremely stable lubricating film and does not contain any hazardous substances whatsoever owing to its bio formulation. Owing to its composition and very low deposition of the lapping medium in the fluid, it only needs to be stirred once a day for approx. 5 min. Depending on the application, the lapping medium can be used undiluted or diluted twice. The medium is water-soluble and therefore easy to clean. Lapping medium BIOLAM Version Grit size Contents Order No. Price Aluminium oxide FEPA 1200 / 3 µm 2 litres 3 638 728 FEPA 1000 / 5 µm 2 litres 3 638 727 FEPA 800 / 7 µm 2 litres 3 638 726 FEPA 600 / 9 µm 2 litres 3 638 725 FEPA 500 / 13 µm 2 litres 3 638 724 FEPA 400 / 17 µm 2 litres 3 638 723 FEPA 360 / 23 µm 2 litres 3 638 722 FEPA 320 / 29 µm 2 litres 3 638 721 Silicon carbide FEPA 1200 / 3 µm 2 litres 3 638 768 FEPA 1000 / 5 µm 2 litres 3 638 767 FEPA 800 / 7 µm 2 litres 3 638 766 FEPA 600 / 9 µm 2 litres 3 638 765 FEPA 500 / 13 µm 2 litres 3 638 764 FEPA 400 / 17 µm 2 litres 3 638 763 FEPA 360 / 23 µm 2 litres 3 638 762 FEPA 320 / 29 µm 2 litres 3 638 761 i Available in two versions: These lapping media are also available in 20-litre containers Other grit sizes and versions (boron carbide and cerium oxide) on request 20

9. Polishing and lapping technology // 9.4. Measuring and testing 9 Interference testing units LAM PLAN 18 W joke 35 W Interference testing units Reflective surfaces are required for measuring the surface quality obtained. Lapped, matt surfaces are therefore polished on the polishing table in order to carry out the test. The flatness can be reliably tested using optical plane face glasses. Our plane face glasses are made of glass ceramics. This material maintains its flatness even when temperatures fluctuate greatly, and it is very scratch-resistant. Plane face glasses are used in conjunction with an interference testing unit. The monochromatic light produced by a sodium vapour lamp has a wavelength of exactly 0.0006 mm (0.6 µm). Since only half the wavelength is used for the measurement, the measuring accuracy is 0.3 μm. Interference testing unit LAM PLAN 18 W Order No. Price Dim. plane face glass Dimensions (W x H x D) Supply voltage Power consumption Weight max. Ø 150 mm 280 x 330 x 390 mm 230 V, 50/60 Hz 18 W 4.2 kg 3 639 552 Interference testing unit joke 35 W Order No. Price Height-adjustable and swivel action Granite base plate Including sodium vapour low-pressure lamp 3 639 553 Dim. plane face glass Dimensions (W x H x D) Supply voltage Power consumption Weight max. 300 mm 400 x 250 x 480 mm 230 V, 50/60 Hz 35 W 27 kg spares Order No. Price Replacement lamp 3 639 587 21

9 9. Polishing and lapping technology // 9.4. Measuring and testing Plane face glasses Optical plane face glasses made of glass ceramics Dimensions Wavelength Order No. Price dual-sided finish (two measuring surfaces) we will be pleased to supply singlesided plane face glasses on request Ø tolerance ± 5 mm other dimensions available Ø 25 mm 1/4 Lambda 3 639 846 Ø 50 mm 1/4 Lambda 3 639 832 Ø 75 mm 1/4 Lambda 3 639 834 Ø 100 mm 1/4 Lambda 3 639 836 Ø 125 mm 1/4 Lambda 3 639 848 Ø 150 mm 1/4 Lambda 3 639 838 Wavelength Order No. Price 1/10 Lambda 3 639 845 1/10 Lambda 3 639 831 1/10 Lambda 3 639 833 1/10 Lambda 3 639 835 1/10 Lambda 3 639 847 1/10 Lambda 3 639 837 Flatness measuring gauges Flatness measuring gauges Flatness measuring gauges are used to check the flatness of lapping disks. This involves positioning the profile rail with the dial gauge on the reference block and setting the dial gauge to 0. The rail is then positioned on the lapping disk. The flatness deviation can be read off on the dial gauge. Fine dial gauge 0.001 mm with impact guard Profile rail with adjustable feet Hard stone reference block Worked on one side in accordance with DIN 876100 Flatness measuring gauges Order No. Price for disk Ø 380 mm 3 637 595 Dimensions (L x W x H) Weight 400 x 50 x 70 mm approx. 6 kg for disk Ø 700 mm 3 637 596 Dimensions (L x W x H) Weight 630 x 50 x 70 mm approx. 11 kg 22

9. Polishing and lapping technology // 9.4. Measuring and testing 9 Polishing table Polishing paper Polishing table To obtain the reflective surfaces required for the flatness test with plane face glasses, the lapped workpieces (with a matt surface following the lapping process) are smoothed on a polishing table covered with polishing paper. Polishing table Order No. Price Dimensions (W x H x D) 355 x 270 x 180 mm 3 639 001 Weight 18 kg Scope of delivery: Including clamping fixture for holding polishing paper rolls 9 and 10 metres long Polishing paper, roll 300 mm width Grit size Length Order No. Price resin bonding 1200 10 m 3 639 013 electrostatic closed 50 m 3 639 014 elutriated grit 200 10 m 3 639 011-0 closed coating 50 m 3 639 012-0 23

Brilliant solutions for perfect surfaces joke Technology GmbH Asselborner Weg 14-16 D-51429 Bergisch Gladbach Tel. +49 (0) 22 04 / 8 39-0 Fax +49 (0) 22 04 / 8 39-61 info@joke.de www.joke.de Copyright joke Technology GmbH 2nd August 2012 issue All rights reserved for technical changes, inaccuracies and printing errors All prices plus statutory VAT in addition to postage and packaging Reprinting, even in excerpts, only with prior written agreement.