#Industry News
OMG filter pumps and MUZZI srl experience
Electroplated tools
The research for tools innovative thin coatings has a strategic importance in several industrial sectors, because of the processes optimization and in order to reduce pollution, social and production costs.
The synergistic approach looking at the system in its complexity considers the tool placed between the machine and the component, participating in the production chain in a “unified manner” with the machine, the lubrication and the equipment.
In oder to solve production problems such as the development of a particular operation or the optimization of difficult materials workability (superalloys and tempered steels), the studies of the tool geometry, the basic materials and in particulary the application of highly innovative coatings (CNx, CBN - Cubic Boron Nitride and nanocomposites coatings) allow to increase the productivity and the cutting speed, with all the annexed benefits.
The cutting tools covered with electroplated diamond by CVD technologies offer the best hardness conditions.
In addition, the high thermal conductivity, the chemical inertia and the low friction coefficient of the coating enable a tool temperatures reduction.
The use of simple polycrystalline diamond inserts, while allowing the same performance during machinings, does not allow the production of tools with complex geometry, such as cutters, tapping tools ..)
The production of polycrystalline diamond carbide tools makes the realization of complex geometries equally difficult, because of the diamond difficult workability which results in high tools costs.
On the other hand, the use of a coating allows to cover all the tools regardless of their shape at acceptable costs.
Diamond coatings are made with CVD technology: a film with a thickness between 5 and 20 microns is applied on the cemented carbides tools thanks to a chemical vapor deposition.
The improving of diamond coatings is an important matter, particularly regarding to the substrate adhesion. In fact, while many manufacturers of diamond coatings are able to deposit structurally good quality coatings, only a few ones are able to make the coating well adhere to the substrate.
Nanocrystalline structure coatings are being developed into researce field; they are characterized by mechanical performance and higher adhesion capacity compared to microcrystalline structure traditional coatings.
Galvanic binder: abrasive layer composition
Diamond and CBN tools with galvanic binder are composed by a metal body which a single layer of grain is placed on; this layer is bonded by another nickel sheet. The result is an open structure tool, perfect for chip discharge.
Strengths:
One important advantage is the possibility to manufacture special tools according to customer specifications. Any geometry could be used as starting point; those tools are extremely flexible with regards to the shapes feasibility.
Tools with galvanic binder are very sharp. Since they consist of only one layer, they are cost-effective.
The desired granulometry choice takes place within a wide range of possibilities. Larger granulometry are suitable for soft materials workability as syntheic ones reinforced wiht fibreglass; harder materials require a finer granumoletry.
The electrodeposited nickel layers are extremely hard and wear resistant. The diamond and CBN strong cohesion allows to build also files and grinding wheels, which are appreciated in treated steels and hard metals machinings.
Tools shapes and batches dimensions have no limitations.
Single tools and diamond or CBN small batches could be produced with the galvanic binder cost-effetvively. Starting from any shapes body made of steel, stainless steel, brass and other materials, it is possible to create a coating both in diamond and in CBN.
To sum up the main advantages:
• The binder type makes these tools very aggressive;
• The coating, consisting of a single layer, is cost-effective;
• it is possible to cover any shape tools by using electrodeposition
• it is possible to produce both one single tool and small batches.
Our customers trust OMG advices in order to select the filter media suitable for their specific needs.
Filter papers, Poliester and PP filter rolls, filter cartridges, PP filter cloths are ready for delivery or easily ordered.
In the Electroplated tools application PF Cartridges are used successfully. They are supplied by the OMG historical partner CARTIERA GRUPPO CORDENONS.
PF cartridges are depth filters with absolute filtration ratings that give high performances due to its stringent production process. The polypropylene fibres used have an increasingly higher density towards the inner core of the cartridge and are thermically bound to reduce the phenomena of fibre release and contaminating substance discharge. These items are 100% thermo-bound polypropylene which complies with FDA regulations. This is achieved without adding binding agents or resins and the cartridges are manufactured on a thermo-welded polypropylene core where the connections are directly applied to ensure a greater strength. The quality of PFA cartridges is certified ISO 9001 and meets all design, production, and quality guarantee issues. PFA complies with USP requirements for class VI for plastic materials. All components comply with the requirements of CFR Title 21 with regard to contact with food products.
CHARACTERISTICS
• Absolute retention rating (Beta 5.000, efficiency 99.98%);
• A density-gradient structure ensures the highest retention of impurities.
• A high porosity degree offers high flow with low start pressure drops;
• Wide chemical compliance;
• The specific thermo-binding process of fibres ensures a low level of extractable compounds;
• The decreasing porosity ensures a long-lasting filter with liquids with a high impurity level. PF range for industrial application is also available, with nominal retention degrees.
APPLICATIONS
Food: Mineral waters, beers, wines, flavourings. Pharmaceutics: Membrane protection pre-filter, ophthalmic products, oral solutions. Chemical: Polymers, Acids, Bases, Solvents. Electronic: High purity water, acids, and electrolytic substances. Cosmetics: Alcohol based products, creams, lotions, essential oils, mouthwash. Galvano-technique: Galvanic bath, rinse solutions, resins, coatings. Water treatment: Drinkable water, Pre/Post-UV, Membrane protection.
The client we are pleased to introduce is Muzzi.
They periodically buy from OMG filter cartridges
They mount them their filter units reaching high filtration results.
