BALL
BEARINGS
Process Research Products
is the world's leading specialist in the field of providing solutions to
manufacturing problems in the Ball Bearing Industry. In the early 1960's
PRP had already developed the first commercial water lapping process with
8150/70 and "temporary glue" Flow on process. Over the last 40
years many new products have been introduced. PRP specialized in providing
products for lapping in the manufacture of Ball Bearings.
CHEMICALS FOR WATER LAPPING
Flow On
The Flow On lapping system was developed as a second generation of water-soluble
products for ball lapping to take advantage of more technically advanced
ingredients now available. We have made improvements in the chemical quality of
the product, improving the quality of the balls produced and simplifying the
operation. Flow On is a semi-synthetic, water soluble coolant used in
conjunction with Abradelap abrasive paste compounds for the lapping of bearings
balls. It is in a concentrated form containing only traces of water and should
be diluted at 14-20 to 1. We have achieved these aims with the Flow On system.
Its advantages are as follows:
•It is nitrite-free
•It works well when diluted with hard water.
•The product is chemically stable and has a long shelf life.
•Better corrosion resistance is built into the product.
•The lapped balls are easier to clean.
•The spent emulsion is easier to split and to dispose of.
•It is only a 2-part system.
General Instructions
Flow On coolant should be initially diluted with water at a ratio of 14 to 1.
Depending upon the performance characteristics, this ratio may be increased to
20 to 1. The diluted product flows onto the balls as they enter the lapping
plates, and is then re-circulated through the system Flow On is suitable for
both individual tanks and central systems.
Abradelap Charging Paste
Abradelap Paste compounds are charging liquids that contain abrasive specially
milled and graded to give a specific particle spread for each lapping operation.
Abradelaps have been developed for use with the Flow On coolant. Currently there
are five grades of Abradelap Paste compounds available. Abradelap Paste is added
either manually or by means of an automatic drip-fee system directly onto the
balls as they enter lapping plates. The amount added depends on load size, ball
diameter, amount of stock to be removed, plate hardness, and machine
characteristics, etc. Process Research Products has assembled case histories
detailing the use of Abradelap under various conditions. Since ball production
methods vary widely from one company to another, we urge potential users to
request information applicable to their specific production conditions.
For single step lapping:Using Abradelap 2T
For finish lapping:4QT
For finest lapping:AWA II
For polishing:Use Abradelap AWA II, GGR (Green Rouge)
Or Abradelap ARR (Red Rouge)
Bakelap – Oil Free Honing Coolant
General Instructions
Bakelap is an oil free honing coolant developed to eliminate oil-based coolants
from the ball lapping operation. Bakelap allows a single aqueous ball cleaning
system to be used whether the balls are lapped in the traditional process
between cast iron plates with Flow On or the Noritake process using Bakelite.
The use of Bakelap completely eliminates the use of honing oil in final ball
lapping operation.
Process Research Products’ Bakelap is a highly concentrated alkaline water based
detergent/coolant used in the ultrafine grinding process known in the ball
bearing industry as Stone Lapping, Noritake Lapping or Bakelite Honing. It is
used at 4% solution in water.
•It has very good rust protection.
•It is a totally aqueous system.
•Excellent detergency & lubrication.
•Fines settle readily.
•It is oil free.
Bakelap
Can be used in individual tanks or central systems. Prior to use, we suggest the
lapping machine be cleaned of oil residue and rinsed with water and then
refilled with a 10% solution of ULTRACLEAN B in water. The ULTRACLEAN B should
be circulated through the machine for 4-6 hours. The tank should then be
drained, refilled with water and BAKELAP. The BAKELAP should be added to the
water at a 4% concentration. The lapping operation can then begin.
Note: If during the process the wheel becomes dark and removal rate drops or the
balls clog on the feed chute, PRP recommends a 50cc addition of concentrated
BAKELAP put on the balls until the wheel turns yellow and starts cutting again.
Plates: Flashing, Grinding, and Lapping
Through our knowledge in the Industry we have over 30 years of experience in
providing high quality cast iron plates for flashing/rill filing, grinding and
lapping.
CAST IRON PLATES
Process Research Products is the world’s largest supplier of custom-made plates
to this industry. Each different type of ball requires special plate matrices
and hardness. We provide specialized plates for every operation whether it is
for ball pen balls, steel shot, ceramics, stainless or 52/100 chrome bearing
balls.
Before we can make a specific recommendation, we will not only need customer
drawings, but also details of the machine type, ball size, material and final
quality required.
Flashing Plates
470-520HB
Process Research Products manufacture Special Cast Iron Flashing Plates in
various chemistries. The graphite size distribution and shape is uniform
throughout and the casting free from cavities. All products are designed to
address customer’s specific needs such as:
•Long Life
•High cut rate
Special chemistries are indicated for difficult to machine materials such as
stainless steel and carbon balls.
Grinding Plates
470-520HB
These are also available in a variety of chemistries and harnesses.
Plates with Inserts
In recent years, many high precision ball producers have requested hardened
plates with soft iron inserts on the leading edge of the inlet gap.
This style of plate was designed to enable customers to CNC the leads in
accurately and they also prevent tool breakage during machining.
Balls manufactured on plates fitted with soft inserts also reduce grinding marks
thus improving ball quality during mass production.
Lapping Plates
120-180 HB Pre Lapping
180-240 HB Finish Lapping
Available in various grades of gray iron and different hardness ranges. These
plates are either sand cast or gravity die cast according to end use.
Geis Plates for Pen Balls
Some customers that make very small balls under 1.0 mm often request very sharp
corners on the feed pockets. We can supply these customers with pockets machined
by wire EDM.
QUALITY CONTROL
After manufacturing in ISO 9002 registered facilities, all Process Research
Products plates undergo rigorous quality checks.
•Emission Spectrospcopy is used to assure proper chemical composition.
•To verify the soundness of each plate, a total surface examination is made
using ultrasound to assure the absence of defects such as inclusions or
porosity.
•Each plate has full traceability back to a unique batch identity and specific
plate number. This information is traceable back to the specific melt.
•An individual Certificate of Conformity is developed and packed with each
shipment. All plates are covered by a comprehensive warranty.
PRODUCT DEVELOPMENT R & D
Process Research Products has in-house R & D capability. We are constantly
testing different plate chemistries in ball production throughout the world.
All Process Research Products plates are manufactured in the EEC by our sister
company in an ISO 9001 : 2000 REGISTERED FACILITY.
Our hardened plates are machined on the
Mounting face and pilot ring after heat treatment.
All Lapping plates are fully machined.
For more detailed information about our
products,
please visit our Technical
Sales Information Database.
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