Hybrid Electroplated Tools
EISEN’s Innovative
Hybrid Electroplated Tools
The Hybrid Electroplated Tool is a revolutionary diamond tool developed for the high-efficiency machining of challenging ceramics, combining the sharpness of electroplated tools with the extended lifespan of metal bond tools. Unlike traditional metal bond or resinoid tools, it exhibits self-sharpening at an ideal rate during use, eliminating the need for a dressing process to clear clogging. This innovative diamond tool enables us to machine tough materials such as SiC (Silicon Carbide) and ZrO₂ (High Purity Zirconia) with high-efficiency in a short period.
Structure of Hybrid Electroplated Tools
Metal bond tools are commonly labeled as 'concentration 100' when the volume ratio of diamond abrasive particles in the abrasive layer is 25%. In the case of hybrid electroplated tools, where over 98% of the abrasive layer is composed of diamond particles, they are labeled as 'concentration 400.' This ultra-high density facilitates highly efficient machining processes.
Processing with Hybrid Electroplated Tools
Processing of circular grooves in silicon carbide (SiC) using hybrid electroplated tools.
Used tool: IZW Φ10.0 #200
Machine: machining centre
Cutting oil: water-soluble cutting oil (external lubrication)
Circumferential speed: 200 m/min
Depth of cut: 0.025 mm/Lap
Feed: 500 mm/min
Machinable distance: approx. 500 m (converted to 10 mm effective length)
Hybrid electroplated tools have an ultra-high-density, multi-layer array of diamonds compared to conventional metal bond tools, which means that they can be machined for longer periods of time without the need for dressing. Even silicon carbide, which is difficult to machine with conventional metal bond tools, can be machined with stable and high efficiency. The main machining method is to cut in the Z direction using the tool end face side.
It has been introduced in the machining of parts for semiconductor manufacturing equipment, the medical machinery industry, the automotive industry and the optical equipment industry.
Processing of arc grooves in zirconia (ZrO₂) using hybrid electroplated tools.
Used tool: IZW Φ5.0 #200
Machine: machining centre
Cutting oil: water-soluble cutting oil (external lubrication)
Circumferential speed: 200 m/min
Depth of cut: 0.05 mm/Lap
Feed: 500 mm/min
Machinable distance: approx. 6000 m (converted to 10 mm effective length)
Hybrid electroplated tools enable incredibly fast machining of dense work materials such as zirconia. They demonstrate their true value in machining operations with large removal volumes. The main machining method is to cut in the Z direction using the end face of the tool.
It has been introduced in the machining of parts for semiconductor manufacturing equipment, the medical machinery industry, the automotive industry and the optical equipment industry.
Processing of arc grooves in silicon nitride (Si₃N₄) using a hybrid electroplated tool.
Used tool: IZW Φ10.0 #100
Machine: machining centre
Cutting oil: water-soluble cutting oil (external lubrication)
Circumferential speed: 125 m/min
Depth of cut: 0.01mm/Lap
Feed: 500 mm/min
Machinable distance: approx. 2000 m (converted to 10 mm effective length)
Hybrid electroplated tools enable incredibly fast machining of difficult-to-machine materials such as silicon nitride. They demonstrate their true value in machining operations with large removal volumes. The main machining method is to cut in the Z direction using the end face of the tool.
It has been introduced in the machining of parts for semiconductor manufacturing equipment, the medical machinery industry, the automotive industry and the optical equipment industry.
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