本部落公告

利豐專門提供 OTEC 表面處理技術皆集中於精密研磨,拋光, deburring, smoothing and polishing. 還有VTD PVD 超硬工具鍍膜 tool coating, 精密光學鍍膜 optical coating, 真空金屬鍍膜 metalization 和 absolute chemie PVD/CVD 退鍍工藝和 EMAG ECM / Precise Electrochemical Machining 精密電化學加工技術, EMAG 硬車削 hard turning, Koepfer 滾齒技術, Reinecker, KARSTENS 內外圓研磨, Naxos-Union曲軸研磨, 凸輪軸, KOPP非圓研磨, SW中心加工機, EMAG 雷射焊接, 自動化設備. oelheld 超高性能研磨切削油/EDM 放電加工液等, 其它非相關資料純粹供同好分享.
2011/10/13

塑料模具拋光方法 -- OTEC 精密研磨拋光技術

2011/10/13 14:19

隨著塑料製品日溢廣泛的應用,如日化用品和飲料包裝容器等,外觀的需要往往要求塑料模具型腔的表面達到鏡面拋光的程度。而生產光學鏡片、鐳射唱片等模具對表面粗糙度要求極高,因而對拋光性的要求也極高。拋光不僅增加工件的美觀,而且能夠改善材料表面的耐腐蝕性、耐磨性,還可以使模具擁有其它優點,如使塑料製品易於脫模,減少生產注塑週期等。因而拋光在塑料模具製作過程中是很重要的一道工序。

1 拋光方法 目前常用的拋光方法有以下幾種:

1.1 機械拋光 機械拋光是靠切削、材料表面塑性變形去掉被拋光後的凸部而得到平滑面的拋光方法,一般使用油石條、羊毛輪、砂紙等,以手工操作為主,特殊零件如回轉體表面,可使用轉台等輔助工具,表面質量 要求高的可採用超精研拋的方法。超精研拋是採用特製的磨具,在含有磨料的研拋液中,緊壓在工件被加工表面上,作高速旋轉運動。利用該技術可以達到Ra0.008μm的表面粗糙度,是各種拋光方法中最高的。光學鏡片模具常採用這種方法。

1.2 化學拋光 化學拋光是讓材料在化學介質中表面微觀凸出的部分較凹部分優先溶解,從而得到平滑面。這種方法的主要優點是不需複雜設備,可以拋光形狀複雜的工件,可以同時拋光很多工件,效率高。化學拋光的核心問題是拋光液的配製。化學拋光得到的表面粗糙度一般為數10μm。

1.3 電解拋光 電解拋光基本原理與化學拋光相同,即靠選擇性的溶解材料表面微小凸出部分,使表面光滑。與化學拋光相比,可以消除陰極反應的影響,效果較好。電化學拋光過程分為兩步: (1)宏觀整平 溶解產物向電解液中擴散,材料表面幾何粗糙下降,Ra>1μm。 (2)微光平整 陽亟亟化,表面光亮度提高,Ra<1μm。

ref: ECM電化學加工(電解加工) http://www.li-fung.biz/PEM-2.htm


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2011/10/13

精密微小切削刀具的製備工藝


微小徑切削刀具
的製備工藝是制約微細切削技術發展的難點之一。精密微細機械磨削和電火花線電極磨削(WEDG)、聚焦離子束濺射(FIB)等特種加工方法是目前主要的微細刀具製備技術。

(1)精密微小磨削工藝

磨削工藝是比較成熟的刀具製備和修整方法。微小刀具的精密磨削工藝主要採用金剛石砂輪,能夠實現高速鋼和硬質合金材料的高效成形。該工藝的要點是:為防止小直徑刀具折斷,應合理確定刃磨時的磨削壓力。通過對砂輪施加振動,可以顯著減小磨削力和最小成形直徑。

精密微小磨削工藝在一定程度上可以滿足微小切削刀具的製備要求,但受磨削力的影響,能夠穩定獲得的刀具最小直徑受到侷限。另外,刃磨工藝容易造成刀具表面劃痕和刃口缺陷,將直接影響加工表面質量和精度水平;磨削熱應力容易引起刀具表層微觀結構的變化;微小立銑刀的同心度和直徑偏離等製造誤差有可能大於微細切削的單齒進給量,成形精度有待提高。


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2011/10/13

VTD: 比類鑽膜 DLC更硬, 更優越的SUPER HARD CARBON FILMS – DIAMOR®

VTD: 比類鑽膜 DLC更硬, 更優越的SUPER HARD CARBON FILMS – DIAMOR®

http://www.li-fung.biz/VTD_NEWS7.html

VTD為德國真空鍍膜技術的佼佼者,其前身為東德的研究機構,技術開發人員就有二千多位,近來更是提供歐盟在太空貓頭鷹計畫中領先的真空光學鍍膜技術,而畫下鍍膜技術新世紀的里程碑,相信其在真空鍍膜的領域上,能為您帶來更有效益的生產方式及品質。



VTD Vakuumtechnik Dresden GmbH and Fraunhofer IWS Dresden are pleased to announce a new development: the DREVA 600-LAM PVD hard material coating plant.

An innovative system for depositing a new generation of DLC coatings on tools and components.
Jointly developed by Fraunhofer IWS Dresden and VTD Vakuumtechnik Dresden GmbH.

Diamor® carbon coating: ultra-hard, amorphous, free from hydrogen (Diamor® is the Trade name of Fraunhofer)

The new laser-arc module - the DREVA 600-LAM's key technological component - enables this Diamor® coating free from hydrogen.
With its new plant, VTD GmbH from Dresden consistently carries on the modular design of the DREVA series which is based on technological flexibility.
Six docking stations from the DREVA 600's basic system enable short-term conversions to and from arc coating or sputtering processes and combinations thereof as well as the integration of the laser arc module. This provides flexibility for an ideal coating in each individual application.


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2011/10/11

what is uECM (micro electrochemical machining)?

what is uECM (micro electrochemical machining)?

Electrochemical machining is a method of removing material by an electro chemical process. It is often characterized as “reverse electroplating,” in that it removes material instead of adding it.

Basic functional diagram of ECM
Basic functional diagram of ECM 


A tool (cathode) is advanced into a workpiece (anode) while a conductive fluid (electrolyte) is injected to the area being machined. A constant dimension gap is left between the tool and workpiece, and, as electrons cross the gap material on the workpiece is dissolved in a process called anodic dissolution. The tool feed rate is the same as the rate of liquefaction of the material on the workpiece. As the desired shape is formed the electrolyte carries away the metal hydroxide formed in the process.


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2011/10/11

why uECM - micro electrochemical machining

why uECM - micro electrochemical machining


Products are becoming smaller, lighter and more compact, and standards and quality requirements are rising. Micro-machining is finding more applications in many products in the aerospace, automotive, medical device, jewelery and consumables industries. There are many forms of micro-machining processes such, as laser machining, electro-discharge machining (EDM), micro-milling and electro-chemical machining (ECM) to name a few. In many instances the SME’s are the driving force behind advance in these technologies.

Diagram of example feature dimensions
example of feature dimensions  

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