Furthermore, the high power of 50 μm maximum down to the extremely fine vibrations of 1μm minimum are achieved. The wider power zone enabled wide-range lapping of large molds and precision lapping of micro-machined molds. Conventional lapping operations that were executed with two or more machines can now be handled with one Laptron machine. The through high-performance operation will achieve drastic improvement in the labor effectiveness.
The newly developed transducer and the control circuit where heat generation is suppressed to the limit enabled stable lapping work without interruption triggered by the safety device even after many hours of use. In addition, the newly developed φ25 mm small diameter hand tool features the use of aluminum with excellent heat dissipation characteristics and a rib design that works as heat dissipation fins and a finger grip. The result is that the user hardly feels fatigue even after continued operation.
Supersonic Wave Mold Washer
Ultra-precision Mold Padding Welder
Supersonic Lapping Machine
Discharge Deposition Equipment
Tips for LAPTRON
■Comparison of Power Zones
The power zones that were divided to three models in the past were integrated into one ALL III machine.The small and stable power for micro palling and the high power required for lapping of large molds can be handled with one ALL III machine.
Aiming at the highest level, we rebuilt the supersonic lapping machine
for which we have been involved in R&D work, aiming for the highest level.
The transducer is subject to flexural oscillations and it expands and contracts in the longitudinal direction. Execution of the transducer movement simulation and analysis of behaviors of the lapping tip end reveal that flexural oscillation overlaps the vibration amplitude of vertical oscillation, thereby causing the tip end to make an elliptical motion. Supersonic lapping becomes possible by performing such motions 18,000 to 26,000 times a second.
Even when a product boasts high power, improvement in efficiency would not be achieved after repeated operational shutdowns caused by heat generation. To solve this problem, we pursued complete heat dissipation. Starting from optimization of the oscillator, we repeated trial and error over reexaminations and redevelopment of the control circuit, in addition to the selection and shape of materials for the chassis. Furthermore, thermographic analysis was applied to the prototype machines, and infinite processes of trial and error were repeated before we could conquer the problems without compromise.
To realize a lapping machine which is capable of performing a series of operations from handling of mirror finish that needs stable micro-vibration under the loaded condition, up to erasure of flaws by using a machine tool where the speed and the high output are demanded by only one machine. For such apparently contradictory needs, we succeeded in setting up the position, shape, and size of the transducer after repeating various analyses and simulations, as well as processes of trial and error. The result is the development of the ideal transducer that is persistent to micro-vibrations and is capable of seamlessly dealing with a wide range of outputs up to high output.
■Example of lapping process
【Mold】 SANWA Logotype Mold 【Steel Used】 NAK80
Using ceramic grinding stone
Using wood tip and diamond paste
【Removal of hardened layer】
Whole surface: ALL III + Ceramic tip #800
【Coarse lapping】 Using ceramic grinding stone
Flat surface: Hand lapping with grinding stone
+ Deep corners: Lapping with ALL III grinding stone
(1) Flat surface #600 -> (2) Flat surface #800 ->
(3) Deep corners: ALL III + Ceramic #800 ->
(4) Flat surface #1000 -> (5) Deep corners: ALL III + Ceramic #1000 ->
(6) Flat surface #1200 -> (7) Deep corners: ALL III + Ceramic #1200
【Intermediate lapping】 Hand finishing with sandpaper
(1) #1000 -> (2) #1200 -> (3) #1500
【Finishing】 Wood tip + Diamond paste
Flat surface: Hand finishing with paste
+ Deep corners: ALL III + Wood + Paste
(1) Flat surface #1800 -> (2) Deep corners: ALL III + Paste #1800 ->
(3) Flat surface #3000 -> (4) Deep corners: ALL III + Paste #3000 ->
(5) Flat surface #5000 -> (6) Deep corners: ALL III + Paste #5000