Electroplated Tools

Since 1980 Muzzi s.r.l. produces a large variety of electroplated tools, diamond and CBN wheels and discs for the mechanical and stone industries.

Our tools are produced with synthetic and natural diamond  and CBN (cubic boron nitride).
Our tools are produced with all available grit sizes, ranging from microgrits (D20) up to very large grits (D1181).

Electroplated wheels and discs are used in a number of different industrial fields where they perform cutting, grinding and finishing operations.

Moreover, Muzzi is active in custom design of special electroplated tools, and we define, together with our customers, the type of abrasive, its size, dimensions and tolerances of the required wheels.

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Electroplated tools : what they are

The electroplated tools are made of a layer of superabrasive crystals, bonded electrochemically to the steel core with a nickel bond.

The nickel coating retains diamond or CBN crystals, whose tips protrude from the bonding approx half their dimension.

Therefore, the adhesion of each single crystal is very good.

At the same time, the cutting edges, protruding out of the bonding surface, make the cut very aggressive, leaving large areas for the debris to flow away.

Types of Electroplated Tools : Diamond and CBN

The term ‘Superabrasive’ refers to:

  • Natural or Synthetic Diamond
  • CBN (Cubic Boron Nitride)

These materials are called  ‘Superabrasives’ because of their hardness which is much greater, compared with standard abrasives such Corundum or Silica Carbide.

Diamond has Hardness = 10 according to Mohs classification. CBN has a slyghtly lower hardness.
Knoop hardness of Diamonf is higher than 8500 Kg/mm2, whilst CBN’s is higher than 4500 Kg/mm2.
Ther are many different types of diamond.

The Natural Diamond is a byproduct of the gems production. Crystal powders are sieved and screened according to their shape, colour and dimension.

Synthetic diamond is industrially produced by sintering, starting from carbon and specific catalysts.
Likewise, CBN does not exist in nature and is produced industrially by applying high temperature and pressure to Born and Nitride. The result of this very specific process is Cubic Boron Nitride.

Different conditions in the sintering process llow the production of superabrasives with different friability, geometry and cutting abilities.

Possible applications of electroplated tools

Muzzi has an extensive manufacturing programme for special diamond and cubic boron nitride (CBN) tools with an electroplated bond. An overview of materials, which can be processed using diamond or cubic boron nitride is provided in the table below:

  • Optical glass
  • Laboratory glass
  • Crystalline glass
  • Fused quartz
  • Precious and semi-precious stone
  • Minerals
  • Oxide ceramics
  • Semiconductor materials
  • Non-oxide ceramics
  • Mixed ceramics
  • Silicate ceramics
  • Natural and artificial stone
  • Hard metals
  • Tungsten carbide
  • Graphite
  • Thermosets and thermoplastics
  • Brake and clutch linings
  • FRP, CFRP, fiberglass, plastics reinforced with kevlar or carbon fibers
  • Soft and foam rubbers
  • Cast resins
  • Frozen foods
  • Pasta products
  • Plastics
  • Window profiles
  • Catalytic converters
  • Cold light fibre optics
  • High-alloyed and tempered steels
  • High-speed steels
  • Powder metal steels
  • Case hardened steels
  • Rubber with steel inserts
  • Cast alloys
  • grey and spheroidal cast iron
  • Magnetic materials

Advantages

These tools have proved themselves reliable in industrial manufacturing for over 50 years.
The advantages are:

  • high stock removal rate
  • consistent grinding profile throughout the entire wheel life
  • low-cost fabrication of the steel core
  • high precision profile
  • worn out tools can be recoated with a new abrasive layer
  • recoating costs less than manufacturing a new tool
  • carrier bodies can be manufactured by the customer

Remark: The grinding allowance has to be taken in account when fabricating the carrier body.

Muzzi diamond and cubic boron nitride tools with an electroplated bond can be used for both wet and dry grinding.

The process parameters of the tools depend on the materials to be processed and the surface finish required.

Our application engineers will be happy to help you to find the correct solution for your manufacturing problems.

FEPA Table

Diamond and cubic boron nitride abrasive grits are classified according to the FEPA ((Fédération Européenne des fabricants de Produits Abrasifs) standard and according to US mesh standard.

Here below all grits available are presented. Most of them are available in stock.

Letter ‘D’ refers to Diamond, while letter ‘B’ refers to CBN.

FEPA Standard(dense)FEPA Standard(wide)US standard mesh(dense)US Standard nesh(wide)Grit size(micron range)
 D 1181 16/18 1180-1000
 D 1182 16/20
 D 1001 18/20 1000-850
 D 851 20/25 850-710
 D/B 852 20/30
 D 711 25/30 710-600
 D 601 30/35 600-500
 D/B 602 30/40
 D 501 35/40 500-425
 D 42740/50
D/B 35645/50355-300
D/B 30150/60300-250
D/B 25160/70250-212
D/B 25260/80
D/B 21370/80212-180
D/B 18180/100180-150
D/B 151100/120150-125
D/B 126120/140125-106
D/B 107140/170106-90
D/B 91170/20090-75
D/B 76200/23075-63
D/B 64230/27063-53
D/B 54270/32553-45
D7B 46325/40045-38
D 2020-10