Diamond Slicing
Sawing. Machining operation in which a powered machine, equipped with a blade having milled or ground teeth, is used to part a material (cut-off) or give it a new shape (contour band sawing, band machining). Four basic types of sawing operations are:
Circular or annular (I.D.) sawing
This process utilizes a rotating circular, toothed blade to cut off the material much as a workshop table or radial saw cuts wood. The ring shaped blade operates under high tension and is held by a precision chick. The cuts made with this method are precise wit little material loss and a good surface finish.
Dicing
Dicing (or diamond-wheel sawing) is used in the micro-electronics industry for fine, accurate, partial and cut-through of exotic, very hard and brittle materials into small squares, or die. Diamond wheel dicing is the most common technique in the industry because of the superior cut quality. It is possible to keep the cut width, depth, straightness, and edge quality within tight tolerances.
Sectioning/Watering
The first stage of sample preparation, metallography, and failure analysis process. A failed part or piece of material is cut off to be studies and observed in order to identify the origin and reason of part/material failure. The main objective is to cause as minimum material deformation to sample as possible and not alter material structure while cutting. Another important consideration is to minimize additional steps required for sample preparation process. Depending on the type of failure, it may be necessary to take several specimens from the area of failure and from adjacent areas.
Gang Sawing
A principal advantage of gang saws is realized when cutting very hard materials. When extremely slow feed rates are necessary, an entire substrate can be cut in just one or two passes with a gang saw. Thus, high-speed production is feasible, and extreme accuracy can be realized. For sawing applications, gang arbors are available to very precise tolerances, maintaining slot widths within ±0.0002 in ( ±5.08 mm), with a gang pitch tolerance of 0.0002 in, non-cumulative.
The best solution for advanced material and non ferrous material high volume production operations. Unlike wafer dicing saws that were designed for more thinner substrate materials. The capabilities of a diamond gang saw are almost limitless. Gang saws have been proven to provide high production volume at minimum cost.
Multi-Blade cutting system makes all cuts simultaneously and automatically separates end cuts from finished pieces. Gang saws are capable of cutting tubes, rods, and flat glass, quartz, carbon, ceramics, plastics, fiber glass, hybrid and exotic materials and most metals. Normal length tolerance is +/- .002". Squareness is +/- 1.0 degrees. Offering Speed, Precision, & Cost Savings. Designed for machining materials such as Glass, Quartz, Ceramics, and Metals. Cut 10 times faster over conventional sawing methods. Gang saws can cut 400 to 6,000 parts per minute 40/1000 to 59 parts in length, Precision Tolerances + 1/200.
Diamond Band Sawing
This process utilizes a flexible, toothed blade is welded into an endless band that rides on wheels driven by two pulleys and is guided through the work cut off or contour. A band saw’s blade is diamond coated by electroplating, a process in which an electrical current deposits the coating onto the blade. This produces a hard, brittle Ni matrix that holds the diamonds in place and permits precise cutting on a variety of materials. A friction saw is a special band saw capable of achieving band velocities of up to 15,000 sfpm or more. Material removal is accomplished in two steps: frictional heat softens the substrate, and the teeth scoop out the molten material. Carbon steel bands are used for flexibility to obtain maximum band life. Method is excellent for cutting extremely hard substrates.
Diamond Grinding
Machining operation in which material is removed from the workpiece by means of abrasive points mounted in a matrix in the form of a wheel, stone, belt, paste, compound, or similar application vehicle. Takes various forms: precision surface grinding (creates flat and squared surfaces); cylindrical grinding (process that creates external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding steps using extremely fine grit to create ultra-smooth surfaces); honing; and disc grinding. Grinding steps take several forms: internal, external, and plunge grinding.
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