LAPPING SYSTEMS & ACCESSORIES
LAPPING SYSTEMS& ACCESSORIESW W W . K E M E T. C O . U K
KemetWhy Choose Kemet Flat Lapping Systems?Kemet Flat Lapping and Polishing Systemsoffer the most efficient and reliable method ofproducing precision flat polished surfaces. Ourflat lapping and polishing machines, and systems,are at the forefront of today’s advanced lappingtechnology, especially when used with KemetDiamond products.Kemet Diamond quality and grading enablesreliable precision lapping to be performed inproduction situations. Each Kemet Diamondproduct is a special blend of diamond powderwith a specific grading and concentration in achemical carrier to give optimum stock removaland surface finish, ease of cleaning, temperatureresistance and lubricity to prevent drying out.Kemet Diamond lapping generates less wasteand is considered more environmentally friendlythan conventional lapping methods.Industries and ApplicationsAerospacePumps & ValvesTechnical CeramicsTurbine PartsHydraulic PumpsSilicon CarbidePumps & ValvesFuel PumpsMechanical SealsPiezo CeramicsGate ValvesFerriteMedical DevicesData StorageAutomotiveSurgical InstrumentsTape HeadsAirbag InitiatorsLaminationsFuel PumpsEngine AssembliesSpacersFibre ScopesHip and Knee JointsPacemaker PartsDisc Drive HeadsCD MouldsTool and DieElectro OpticsPrinting PlatesLaser Rods and PrismsMoulds and InsertsSlitter KnivesExtrusion DiesPlano OpticsFibre OpticsSensorsSapphireALN2Alumina - ZirconiaDiesel InjectorsPiston Rings
Benefits of Kemet’sA d v a n c e d L a p p i n g Te c h n o l o g yKemet offers a complete range of lapping and polishing systems for industry. Special purpose machinescan be developed for specific applications. Significant reduction in lapping costs Faster polishing process Cleaner environment conditions Pre set parameters Reduced inspection requirements Reduced rejections One operation surface finish Optimum geometry and surface finish Semi skilled operation Easier product cleaning Faster material removal Better utilisation of machine timeKEMET BALL POLISHING MACHINE3
KemetDiamond AbrasivesKemet International is one of the world’s leading manufacturers of Diamond Abrasive Products usedin research and industry. The wide range of standard formulations include liquids, pastes, suspensions,gels and sticks. Our laboratories have over 50 years experience and have developed specialformulations for most lapping and polishing processes. These range from basic hand lappingoperations to fully automatic double sided lapping systems.4
Features C onsistency of PerformanceManufactured under a Quality System registeredby BSI Cert No QO5919 ISO 9001:2008 P recise and Superfine Surface FinishesAvailable in an extensive range of differentmicron sizes, containing only virgin DiamondPowder, graded to closer tolerances than theinternationally recognised standardsStandard Kemet Liquid Diamond ProductsType KAn excellent, general purpose, low viscosity oil/wateremulsion suitable for most applications.Type W SeriesWater soluble Liquid Diamond available invarious viscosities. Recommended where lapping/polishing must be carried out in the absence ofoil based materials.Type OLow viscosity oil soluble Liquid Diamond withenhanced cleaning properties.Technical DataFinal PolishingLapping &Pre-PolishingRapid Stock Removal E fficiency and EconomyUniform suspension of Diamond Powders inspecially formulated chemical carriers, ensuresthat the diamond cuts and polishes withmaximum effectiveness R eduction in Lapping CostsSuitable for dispensing with the KemetElectronic System, thus eliminating wastage andreducing lapping costs E asy Product CleaningSpecially formulated Liquid Diamond Productsenable parts to be cleaned easily.Micron Size1/10/4Kemet Liquid Diamond is1/2 normally supplied in units11of 400g, 2000g or 2500g.2Special micron sizes,3 formulae, colour coding andother packaging sizes for6specific applications are8available.10Concentrations are standard14strong and extra strong.Specials are manufactured.25Kemet Lubricating FluidsSpecially developed to ensure that KemetLiquid Diamond cuts and polishes with maximumefficiency. Two Lubricating Fluids arerecommended – Type K, a mineral oil basedlubricant, and Type W, a water based lubricant.455
KemetFlat Lapping PlatesKemet composite lapping plates are manufacturedfrom a homogeneous mixture of synthetic resins,metal particles and other materials. The plates areideal for today’s advanced lapping technology,especially when used with Kemet Liquid Diamond.Features H olds diamond particles firmly, ensuring bothefficient stock removal and repetitivecomponent surface finish. D uctile qualities cushion the diamond particles,preventing damage to the workpiece. P roduced in varying hardness values sothat even the softest material can, withoutimpregnation, be safely lapped with diamondparticles. D issipates heat and prevents laminar flowof lapped surfaces. Easy control for optimum flatness. L apping/polishing plates available to fit allmakes of lapping machines with platediameters up to 3000mm. S upplied with a cast iron backing plate formaximum stability.Kemet Lapping PlatesKemet IronThe most commonly used plate. For general purpose stock removal and lapping operationsKemet XPGives improved flat polished surfaces on manymaterials. Flat mirror surfaces can be producedon many hard materialsKemet CopperUsed to lap softer materials where fine lappingand polishing are the primary requirementsKemet TinOne of the softest Kemet Plates used for mirrorpolishing with fine grades of Kemet LiquidDiamond.6
Kemet Flat Lapping PlatesStandard Kemet Lapping PlatesThese plates are normally supplied mountedon a cast iron backing plate for maximumstability. They are recommended for generaland heavy-duty work where high precisionflatness and surface finish are required.Standard PlateKemet Lift Off Disc SystemKemet Lapping Plates are also available asLift Off Discs, for machines up to 610mm (24")diameter. Discs are supplied mounted on analuminium backing plate, which locates on to analuminium drive plate by means of three pegs.Lift Off Discs can be easily changed and arerecommended for light duty work where generalflatness and precision finish are required.Lift Off Disc AssemblyGroovingKemet Lapping Plates can be supplied grooved tosuit specific applications.ConcentricSquareSpiralKemet Annular Grooved PlatesThese plates are designed for precision shoulderlapping of a wide range of parts, such as fuelpump gear faces and pressure relief valve caps.Groove width and depth of plates need to bespecified when ordering.WidthDepthAnnular Groove7
KemetFlat Lapping MachinesFeaturesKEMET 15/20 MODELSBench Mounted Precision Diamond FlatLapping and Polishing Machines Variable speedBoth Kemet 15 and 20 models are benchmounted machines with rigid metal constructionand height adjustable work tables. P roduces optically flat surfaces with highprecision surface finishThe machines incorporate digital processtimers and automatic Liquid DiamondDispensing Systems.Options Suitable for bench mounting R educes lapping costs – fully controllable KemetElectronic Dispensing System accurately metersdiamond abrasive onto the lapping plate R educes waste – only small quantities ofdiamond abrasive and non-toxic fluids are used B uilt in abrasive system for conditioningKemet plates Suitable for lift off disc system Electrical System complies with EN 60 204 Fixed speed Easy to adapt for special lapping applications Pneumatic lift on model 20" TransportableOther versions COL-K Chemical polishing version Clipper Blade sharpening machineKEMET 158KEMET 20
FeaturesKEMET 24/36 MODELSBoth Kemet 24 and 36 machines have rigidwelded tubular section steel frames, supportingthe gearbox, drive motor and worktable. They alsohouse a integral abrasive compound feed andwaste tanks behind lift-off panels. The machinesincorporate soft starting features, which smoothlyaccelerate the lapping plate from stand still to fullspeed, over a pre-determined time period. P roduces optically flat surfaces with highprecision surface finish R educes lapping costs – fully controllable KemetElectronic Dispensing System accurately metersdiamond abrasive onto the lapping plate B uilt in abrasive system for conditioningKemet Plates Suitable for large parts or large volumeproductionOptions Electrical System complies with EN 60 204 Variable speed Temperature control Drop table Pneumatic lift or open face 3 or 4 ring versions COL-K Chemical Polishing versions Light beam guardingKEMET 24 OPEN FACEKEMET 36 PNEUMATIC LIFT9
KemetFlat Lapping MachinesKemet Lapping MachineCapacity Chart1520243648567284Components per conditioning ring based on typical loading of approximately 60% ring surface area.KEMET MODELDIA OF PARTSMMIN152024243636485672843 Ring3 Ring3 Ring4 Ring3 Ring4 Ring4 Ring4 Ring4 Ring4 11122461015The above data is for using standard loading procedures. It is often possible to extend the capacity of a machine utilising special workholding arrangementsand fixtures.10
Kemet MachineSpecifications15KEMET m/c rpm333 or 43 or 43 or 43 or 44mm140191248 209368 322505 432578 530692in5.57.59.75 8.2514.5 126919.9 1722.7 0v-1Ph-50Hz220v-1Ph-50Hz220v or220v or220v or220v or220v oror 380v oror 380v or380v or380v or380v or380v or380v 50Hz3Ph-50Hz3Ph-50Hz3Ph-50Hz3Ph-50HzMAIN DRIVE MOTOR0.37kW0.75kW1.5kW4.1kW7.5kW11kW15kWABRASIVE PUMP 876kg--700kg1530kg3145kg5273kg7930kgLAPPING PLATEOUTSIDE DIAMETER70rpmLAPPING PLATE SPEEDNO OF CONDITIONINGRINGSCONDITIONING RINGINSIDE DIAMETERHEIGHT OF OPEN FACEMACHINEHEIGHT OF PNEUMATICLIFT MACHINEWORKING HEIGHTWIDTH OF MACHINEDEPTH OF MACHINESTANDARD ELECTRICALSUPPLYGROSS WEIGHTOPEN FACEEXPORT PACKEDNETT WEIGHTOPEN FACEGROSS WEIGHTPNEUMATIC LIFTEXPORT PACKEDNETT WEIGHTPNEUMATIC LIFTNOTE:- Metric/Imperial conversions are approximate. All dimensions are for machines fitted with KEMET Electronic Spray Systems.In the interests of development we reserve the right to change specifications without notice.11
KemetSpherical Lapping and Polishing SystemCapabilities Fully guarded with auto lifting door access.To lap and polish pre-machined spherical balls andcups to a mirror finish with roundness usuallybetter than 3 microns. Dual process timers.System Features 6 motors all with independent variable speed toprovide complete control. Lighting provided. Smooth and silent running. Comes complete with initial tooling set Lapping and Polishing pressures appliedpneumatically. CE marked. Simple change from ball to cup polishing action. Size: 1600mm (W) x 820mm (D) x 2500mm (H) Average process time less than 5 mins. Electrical: 230.1.50 supply Low running costs. Air: 3 Bar Max. Manual and Jogging facility provided for setting up.12 Single button process start. Full manual and training provided.
KemetDispensing SystemsThe Kemet Electronic Dispenser distributes KemetLiquid Diamond and Lubricating Fluid by means oftouch sensitive settings. The digital display showsdispensing intervals, durations and air pressure ata glance. Dispensing is achieved to an accuracyof 0.2 gm, eliminating wastage and simplifyingcost control.The Kemet Liquid Diamond Stirrer Unit maintainsa consistent distribution of diamond particleswithin the slurry by using a small non-contaminantplastic coated paddle magnet, which ensureseven diamond suspension. The Kemet DualDispensing Bar can be positioned to dispenseLiquid Diamond and Lubricating Fluid accuratelyon to the plate without spray bounce.Features S upplied as standard with Kemet Flat Lappingand Polishing Machines and Plates E asily fitted to existing conventional Flat LappingMachines to improve productivity F ully controlled metering of Kemet LiquidDiamond and Lubricating Fluid usingindependent pressure and time settings Easy to install and operate Electrical system complies with EN 60 204.Kemet Electronic DispenserDispenses Kemet Liquid Diamond and Lubricating Fluid automatically at pre-set intervals in conjunction with a lapping andpolishing machine cycle timer.Height150mmWidth230mmDepth (exc. air filter)150mmNett Weight3.74kgCODE360499Air requirements1 Bar min5 Bar maxAdjustable durationof spray1-9 secondsAir pressureDual circuitAir pressure displayBar or psiAdjustable intervalsof spray1-999 secondsSpray memoryStandardManual overrideStandardElectrical supply110V or220V - 240V50Hz or 60Hz(self adjusting for supply voltage & frequency)Kemet Dual Dispensing Bar & BottlesKemet Liquid Diamond Stirrer UnitSupplied complete with two bottles and plastic tubing. Fullyadjustable head for vertical and radial positioning.Quiet electric unit has fully variable speed control and isprovided with a magnetic stirrer al supply50Hz or rdLongLength340mm495mmReach260mm415mmAdjustable height100mmSection of head20mm x 20mmBottle capacityCODE360536Kemet Single Spray HeadSupplied with bottle, cap and plastic tubing.StandardLongExtra ctronic DispenserLiquid Diamond Stirrer UnitDual Dispensing Bar & BottlesSingle Spray Head13
KemetFlatness Measuring EquipmentFor use with Kemet Flat Lapping and PolishingSystems, Kemet Flatness Measuring Equipmentis designed to assist in the measurement andmaintenance of surface flatness.Optical Flat Light Box Stands are available for usewith large Optical Flats.Kemet Monochromatic LightProduces clear flatness readings when used withKemet Optical Flats. The compact designed Lightis easily transportable and uses a sodium long-lifelight source. Supplied with a flatness readinginterpretation chart.Kemet Monochromatic LightMonochromatic Light230V50Hz or 60Hz110V50Hz or 60HzCODE361201361211Kemet Monochromatic Light14
Kemet Flatness GaugesKemet Optical FlatsThe Flatness Gauges are used to monitor lappingplate flatness, which, in turn, gives an indicationof component flatness. Available for most machinesizes, in metric calibration, the gauges aresupplied in a case with a master setting block.Full instructions are provided.Produced from Quartz, Kemet Optical Flatsare available in single and double sided,standard sizes from 25mm up to 300mmdiameter. They are supplied with Certificateof Conformity together with full instructions.National Physical Laboratory Certificates arealso available. Special optical flats are availableon request. Kemet offers an optical flatreconditioning and calibration service.Kemet Optical FlatsDiametermmin9" Flatness GaugesKemet Flatness GaugeType LCODEMETRICSuitable for Lapping Plates361304380mm (15") dia and aboveCODEAccuracyLight BandsCODESingle sided Double 1247Larger Optical Flats on request.Flatness Reading Wall Charts are availableupon requestKemet Optical Flats15
KemetHand Lapping KitsKemet Portable Hand Lapping KitsType L Kit for lappingLeaking pumps, valves and seals cause manyproblems, leading to wastage, poor performance,unnecessary costs, even health hazards. KemetPortable Lapping Kits enable refurbishment to becarried out on site, reducing expensive downtime.Components manufactured from ceramics,tungsten carbide, stellite, brass, steel, siliconcarbide, ni-resist etc, can be lapped and/orContains:polished by hand in minutes rather than hours.The kits are also ideal for low volume production,where it is not economical to purchase a lappingor polishing machine. Kemet Iron Plate (for lapping), 348mm dia.,with concentric grooving. 1 x 10g Kemet Diamond Compound ApplicationStick - 25 micron 1 x Kemet OS Lubricating Fluid 1 x Case with operating instructions.Type P Kit for polishingContains: Kemet XP Plate (for polishing), 348mm dia.,with concentric grooving. 1 x 10g Kemet Diamond Compound ApplicationStick - 3 micron 1 x Kemet OS Lubricating Fluid 1 x Case with operating instructions.3 Lap Kit for lapping and polishingContains: Kemet Iron Plate (for lapping), 150mm dia.,with non skid backing K emet XP Plate (for smoothing), 150mm dia.,with non skid backing K emet Tin Plate (for polishing), 150mm dia.,with non skid backing 1 x 10g Kemet Diamond Compound ApplicationStick – 25 micron 1 x 10g Kemet Diamond Compound ApplicationStick – 8 micron 1 x 10g Kemet Diamond Compound ApplicationStick – 3 micron 1 x Kemet OS Lubricating Fluid 1 x Case with operating instructions.16Kemet Hand Lapping KitsCODETYPE L KIT352216TYPE P KIT3522083 LAP KIT352206
Kemet Polishing PadsKemet Polishing PadsFlat polished surfaces can only be produced onmany softer materials with the use of polishingpads. These are available to suit most flatlapping machines. Kemet offer the widest range ofself-adhesive and metallic backed polishing pads,of which there are three general types:Synthetic Silk PadsChemo Textile PadsNon woven pads manufactured specially forpolishing processes.PSU - available in medium and hard. Used withDiamond and Non Diamond abrasives. A goodgeneral purpose pad with a relatively long life.A range of synthetic silk pads with a durablewoven structure that produces flat mirrorsurfaces on stainless steels, stellite and manyother metals.ASFL - for optimum flat mirror polishing of manymetals. This pad is available with adhesive resistance to oil or water, to suit the polishing abrasivebeing used.ASF - this silk pad has a self-adhesive cloth backing which is resistant to water. It produces mirrorsurfaces, but is more suitable for cosmetic finisheson products, such as jewellery, where flatness isnot crucial.CHEM-H - for use with COL-K polish for chemicalmechanical polishing processes, which arerequired for many specialised materials, such astitanium and cobalt chrome.Nap ClothsParticularly suitable for the softer materialsand metals.MRE - Synthetic flock on a flexible waterproof carrier. A more heavy duty cloth for use with 6 micronKemet Diamond Slurry and finer. Colour: Red.Kemet Polishing Pads - Self AdhesivePad Type380mm (15")610mm .A.KEMET MAGNETIC CLOTH SYSTEMKemet Polishing Pads - Metallic Fibre Backed PadsAdvantages of theKemet Magnetic Cloth SystemPad Type380mm (15")610mm (24")916mm 5 Easy to change clothsPSU-MM341814341837341838 Cloths last 828 No adhesive breakdown problemsKemet Polishing Pads - Magnetic Backing DiscsPad Type380mm (15")610mm (24")916mm (36")Magnetic Disc345185345197345196 Faster and cleaner cloth changes No metal disc i
Kemet Diamond quality and grading enables reliable precision lapping to be performed in production situations. Each Kemet Diamond product is a special blend of diamond powder with a specific grading and concentration in a chemical carrier to give optimum stock remo
The quality of lapping differs from operator to operator and the results are highly inconsistent. The material removal rate, surface finish, and flatness all depend on the proper control of lapping parameters such as . (Manual Lapping).95 Table 9 Analysis of Variance Table for Surface Flatn
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Kemet Diamond quality and grading enables reliable precision lapping to be performed in production situations. Now a truly international organisation, Kemet’s activities span the world, spearheaded by companies in nine countries, all sharing the same commitment
4.4 Power ON the tool; for lapping make sure the roller arm is set to "STATIC" 4.5 Set the slurry scraper so that the scraper is just touching the edge of the plate 4.6 Deliver some slurry on the plate by rotating the plate and turning ON Abrasive Autofeed 4.7 Place the jig between rollers and hold the jig's central ring up with your fingers 4.8 Reset the timer and start rotating slowly
stage, the influence of lapping parameters such as pressure p, speed v and time t, on the contamination intensity were found. Complementary tests included the evaluation of the influence of micrograins size and concentration in the abrasive slurry as well
Polishing processes are critical to high value production processes such as IC manufacturing. The fundamental material removal mechanisms, howeve, are poorly understood. Technological outputs (e.g., surface finish, sub-surface damage, part shape) and throughput of lapping and polishing processes are affected by a large number of variables.
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3 Draft as of 3 ebruary 2020 2019 Novel Coronavirus (2019-nCoV): Strategic Preparedness and Response Plan Epidemiological overview as of 1 February 2020 A total of 11953 confirmed cases of 2019‑nCoV have been reported worldwide (figure 2); Of the total cases reported, 11821 cases have been reported from China; In China, 60.5% of all cases since the start of the outbreak have been .
