Electroplated Diamond Tools - Manufactured by UKAM Industrial Superhard Tools

UKAM Industrial Superhard Tools manufactures Precision Electroplated Diamond Products from 0.5 microns to 20 grit (diamond mesh size) in Synthetic, Natural Diamond or CBN (cubic boron nitride). For a large variety of applications, materials, and industries. Electroplated Diamond Products Manufactured by UKAM Industrial are Multi Layered. They have 3 layers of diamonds, not just 1 layer of diamonds like conventional electroplated diamond tools.

This provides longer drilling life, faster and freer machining action, & more consistent performance. UKAM Industrial is also capable of evenly spacing and orienting diamonds in its coatings by utilizing SMART CUT™ technology. Electroplated Diamond Products provide:

Free Cutting Action - better removal rates and less thermal damage to the part
Good Form Holding Characteristics - hold simple and intricate forms for the entire life of the tool or wheel, from first grind to last.
Maximum Abrasive Particle Exposure
High Stock/Material Removal Rates - Lower long term cost with the potential reduction or elimination of time associated with set-up, dressing and tool changes.
Reusable - striped & replated with potential savings of 25% over new electroplated products.

Electroplated diamond products usually have a single layer of diamonds, held by a tough durable nickel alloy. Electroplated diamond products are ale to retain their original shape and dimensions thought their working life. Unlike sintered (meal bond) or resin bond diamond products, where diamond particles are buried in bond and held together by metal or resin binder deep inside. Electroplating allows diamond particles to protrude from the bond matrix, providing a free, faster cutting action with minimum heat generation.

Just about any shape can be plated with almost any size diamond (superabrasive). Electroplating can also provide production cost savings because the part's finish shape can be easily produced by the plated tool. We can produce just about any type or shape of electroplated tools, from print supplied by you, or we will plate a blank your provide.

UKAM Industrial Superhard Tools is also the first company to develop SMART CUT™ technology, advanced technology that allows every diamond to be oriented and evenly positioned inside diamond bond matrix. Every diamonds works in the right place and at the right time, where you need it most Find out more about SMART CUT™ technology >>>

UKAM Industrial Superhard Tools has over 50 years of experience in manufacturing, research, and development. We are at the forefront of technology and are constantly engaged in Research & Development. Following the belief: "There is always room for improvement" We continue to raise standards for the whole industry. Our products are used in High Production, Research & Development, and Hobby applications. Customers include some of the leading Fortune 500 companies, Military, Science & Space Organizations, Small Machine Shops, Contractors & Hobby Enthusiasts. We also pride ourselves in manufacturing tools that are used in our nations mission critical applications, involving defense and national security. As well as exciting & breakthrough fields such as: MEMS & Nano Technology.

Examples of Multi-Layered Electroplated Diamond Products manufactured by UKAM Industrial Superhard Tools

Multi-Layered Electroplated Diamond Core Drills

Diamond Micro & Diamond Solid Thin Drills

Diamond Micro Drills

Diamond Laps

Diamond Band Saw Blades

Diamond Core Drills with center pilot

UKAM Industrial Superhard Tools has over 50 years of experience in manufacturing a large variety of products for industry, Research & Development, as well as hobby. Only the highest quality synthetic or natural diamonds and raw materials are used in the manufacturing process. The highest quality standards and product consistency is maintained, using sophisticated inspection and measurement equipment. Standard (off the shelve) electroplated diamond products include: diamond drills, diamond micro drills, ultra thin diamond blades, diamond burs, diamond grinding wheels, and much more.

In addition to manufacturing standard electroplated diamond products, UKAM Industrial Superhard Tools can electroplate diamonds on just about any material or substrate per customer drawing and specifications. Our stripping System allows a tool blank to be Stripped & Replated as many as 100 times over before loosing .0000001" of the surface. We pride ourselves in working with some of the leading glass, composite, semiconductor, stone, and optics manufacturers.

EXAMPLES OF CUSTOM MADE ELECTROPLATED DIAMOND TOOLS

UKAM Industrial Superhard Tools can design and manufacture just about any diamond product to better fit you needs, specifications, standards, and requests. Our Experienced Engineers and Application laboratory, equipped with some of the latest Slicing, Dicing, Wafering, Drilling, & Micro Drilling Equipment is available to help you develop not only the right tools, but the Right Process for your specific Material/Application. We will work with you to determine your needs, and recommend the right solution for your specific material/application. Let us help you improve your Diamond Machining operation to its ultimate level of efficiency.

UKAM Industrial Superhard Tools is constantly engaged in Manufacturing, Research & Development, and Client Machining Process Optimization. Some of these breakthroughs and achievements are regularly contributed and presented in technical articles or lectures for many leading industry publications (magazines) and trade associations. See list of articles and presentations published. More >>>

High Precision & Industrial Electroplated (nickel bond) Diamond Tools

Manufactured for following Applications:

Advanced Ceramics

Composites

Glass

Lapidary

Medical Devices

Metallography

Material Science

Precision Optics

Semiconductor

Stone

Whatever your goal or objective, UKAM Industrial Superhard Tools can help you get there faster. Expect MORE from your Tools.

Over past 50 years, Over 35,000 different types & specification diamond tools have been manufactured by UKAM Industrial Superhard Tools.

SELECTING THE RIGHT DIAMOND TOOL FOR YOUR APPLICATION

MATERIALS - APPLICATIONS - EQUIPMENT

Typical Electroplated Diamond Tool Applications / Materials Used On:

Fiberglass	Polyesters	Melamine	Carbon
Graphite	Asbestos	Ceramics	Pure Glass
Refractory	Micarta	Refrasil	Astralite
Green Carbide	Carbide	Ferrites	Quartz
Silicon	Stone	Marble	Porcelain
Alumina	Glass Bonded Mica	Silicone	Onyx
Beryllium Oxide	Barium Titanate	Transmission Bands	Clutch Linings
Brake Linings	Epoxy	Taped Graphite	Glass Laminated
Cerments	Optical Materials	Composites	AND MANY OTHERS

Electroplated Diamond Tools are Frequently used in following Industries:

Aircraft	Boast	Aerospace	Yacht
Circuit Board	Automotive	Construction	Ceramics
Missle	Casket	Paneling	Tank (Water & Acid)
Diving Board	Pool Slide	Swimming Pool	Form Grinding
Marble	Glass	Composites	AND MANY OTHERS

Diamond - mainly used on any nonferrous materials, such as: carbides, ceramics, glass, fiberglass, reinforced plastics etc., and CBN is for use on ferrous materials, tool and diesteels, high alloy steels and nickel rich alloys.

CBN (cubic boron nitride) - mainly used on tool and die steels, high alloy steels, and nickel rich alloys.

To obtain optimum diamond machining results, from our electroplated diamond tools. We recommend following general grinding guideline with both Diamond and CBN tools:

Diamond Definition	Diamond Mesh Size	Thickness of Diamond Coating	Recommended Application	Size of each particle A	Size of each particle B
Saw Grit	40/60	0.036"	Sawing	0.016"	0.002"
Super Course	60/80	0.023"	Roughing (Heavy Stock Removal)	0.010"	0.0015"
Large Course	80/100	0.0186"	Medium Roughing (General Grinding)	0.008"	0.0013"
Course	100/120	0.0174"	Semi Roughing (Semifinish Grinding)	0.0075"	0.0012"
Medium	140/170	0.012"	Rough Finishing (Finish Grinding)	0.005"	0.001"
Fine	200/230	0.008"	Finishing	0.003"	0.001"
Extra Fine	270/325	0.0064"	Fine finishing	0.0025"	0.0007"
Super Fine	325/400	0.005"	Extra finishing	0.002"	0.0005"
45 Microns*	400/500	0.0034"	Super finishing	0.0015"	0.0002"
30 Microns*	500/600	0.003"	Polishing	0.0013"	0.0002"
15 Microns*	800/1200	0.0022"	Polishing	0.001"	0.0001"
*9 Microns 8/10 6/12**	1,800	0.0007"	Polishing	0.00035"	0.00008"
*6 Microns 4/8**	3,000	0.00048"	Fine polishing	0.00024"	0.00008"
3 Microns*	8,000	0.00032"	Extra polishing	0.00016"	0.0000075"

* Not recommended for removing more than .000001" per pass.

SURFACE FINISH REQUIREMENTS

Due to the aggressive nature of diamond and CBN electroplated products, "super fine" finishes can be difficult to achieve. The following will help you select the appropriate grit size to achieve your required finish:

GRIT SIZE	APPROXIMATE RMS
30/40	200-250+
40/50	150-200
60/80	125-150
80/100	90+125
100/120	64-90
120/140	48-64
140/170	32-48
170/200	24-32
200/230	20-24
230/270	16-20
270/325	14-16
45 Micron (400)	13-14
30 Micron (600)	12
15 Micron (1200)	12

*When converting from conventional aluminum oxide or silicon carbide wheels to electroplated products, double the conventional grit size to find the equivalent electroplated grit size. For example: a 60 grit Aluminum Oxide would equal 120 grit electroplated.

DIAMOND PARTICLE SIZE CHART

DIAMOND GRIT SIZE

LAYER
THICKNESS

STANDARD
TOLERANCE
+/-

30/40
40/50
60/80
80/100
100/120
120/140
140/170
170/200
200/230
230/270
270/325
325/400
45 Micron (400)
30 Micron (600)
15 Micron (1200)

0.022"
0.018
0.010
0.007
0.0065
0.006
0.005
0.0045
0.004
0.0035
0.003
0.0025
0.002
0.0015
0.001

0.010"
0.006
0.004
0.003
0.003
0.002
0.002
0.002
0.002
0.001
0.001
0.001
0.001
0.001
0.001

Total tool tolerance for electroplated diamond tools is determined by sum of backing material tolerance and respective profile tolerance. Specific tolerances are available on many tools upon request.

ELECTROPLATED DIAMOND TOOLS SHAPE & ACCURACY

Electroplated diamond products are an excellent choice for applications requiring repeating specific shapes or close tolerances or both. Its important for the End User / Customer to be familiar with the specific tolerances and sizes of the abrasive particles to insure the manufacturing feasibility of the electroplated diamond wheel or tool.

GUIDE FOR MACHINING BLANKS WITH RADIUS

For example, the female radius in the steel blank must be larger than the finished diamond plated size and so naturally a male radius must be smaller. Just how much larger or smaller the radius must be depends on the diamond grit (mesh) size selected. Based on the required grit size and the specifications on the form we can determine the manufacturing feasibility of your electroplated diamond tool.

Female radius on the steel blank must be larger than the finished size required

Example: If a 0.250" female radius is needed with 100/120 Grit.- How much larger than the finished radius should the tool radius be? 100/120=0.0075", therefore 0.250" + 0.0075=0.2575

Male radius on the steel blank must be smaller than the finished size required

Example: If a 0.250" male radius is needed with 100/120 Grit.- How much smaller than the finished radius should the tool radius be? 100/120=0.0075", therefore 0.250" - 0.0075=0.2425

RECOMMENDED STEEL BLANK MATERIALS

Blank material hardness should be about 50 to 60 on Rockwell scale of hardness. Diamonds usually provide best adhesion to materials with high carbon content. High speed steels such as 4130, 4140 usually used for most blanks to be electroplated with diamonds. Steel used should have no lead content.

TYPICAL SPEEDS & FEEDS for ELECTROPLATED DIAMOND TOOLS

Once you have determined the appropriate diamond mesh (grit size) for your application, it's important to know if you have the speeds necessary to have your diamond tools operate to its ultimate potential. This is particularly important with CBN which requires high speeds and pressure to perform successfully.

    Feed rates are dependent on workpiece material ranging from fine furnishing cuts
      to high energy deep grinding. Ask your UKAM Industrial Superhard Tools engineer / representative for recommendations on your specific application

          Diamond: 5,000 to 6,000 SFPM (Surface Feet Per Minute)

          CBN: 6,500 to 12,000 SFPM

         SFPM = Wheel Speed in RPM's X Wheel Diameter in Inches X .262

COOLANTS & ELECTROPLATED DIAMOND TOOLS

Diamond (Synthetic or Natural)
Electroplated diamond tools can be used dry, however, the life & performance of the tool will be significantly superior when used with coolant. Frequent coolants used with diamond electroplated tools include plain water or Synthetic Water Soluble Coolants, such as SMART CUT coolant. Synthetic water soluble coolants are recommended and will promote superior tools performance, life, and consistency.

CBN (Cubic Boron Nitride / Borazon)
Straight oil coolants are frequently used with CBN (cubic boron nitride) diamond tools. Recently due to rising health and environmental issues associated with straight oil coolants, most companies are are using new synthetic water soluble oil coolants, such as SMART CUT coolant. Many companies today are achieving success with these water based oil coolants when working with CBN tools. Please remember that life of electroplated diamond tools will be lower with used dry or with water based coolants.

What you should know before you buy your next diamond tool?

UKAM Industrial Superhard Tools Division of LEL Diamond Tools International, Inc.

28231 Avenue Crocker, Unit 80 Valencia, CA 91355 Phone: (661) 257-2288 Fax: (661) 257-3833

e-mail: lel@ukam.com


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