Finishing Solutions for Manufacture & Repair of Ball Valves and Seals

With precision cutting action, less time and pressure is needed per lapping stage reducing scratching and operator fatigue.  

•  Elimination of Errant Scratches
•  Reduced Compound Usage & Cost
•  Improved Cut Rates
•  Achieve Desired Surface Finishes Faster 

Diamond Gels
Thinner than pastes, but still thick enough to be applied with a syringe. The thinner consistency results in slower drying, reducing scratching while maintaining good adhesion to lapping tools and parts. 

Diamond Pastes
Thick formulations dispensed from a syringe or jar manually spread across the part. Pastes are the most common form of diamond compound for hand polishing and typically used with a companion lubricant. 

PREVIOUS PROCESS:

1.  Poorly graded diamond compound.
2.  Frequent scratches during progressions resulting in repeating steps, scrap of some balls/seats due to depth of scratch or lack of coating thickness.
3.  Compounds dried out quickly, excess application, repeat each step numerous times.
4.  Excessive force required to get cutting action.
5.  Up to 15% failure rate at test stand.

NEW PROCESS RESULTS:

1.  Using Engis Hyprez Diamond Gel errant scratches were eliminated during progressions.
2.  Longer useful life per charge (no drying out) with faster cut rates and less pressure.
3.  Doubled run time between charges reducing charges by 20% and 15%.
4.  Improved operator ergonomics.
5.  25% reduction in lapping time.
6.  Test stand failures below 1%.
7.  Increased plant capacity for repairs due to less rework.

REQUIREMENTS: Customer was currently processing these parts on a cast iron plate using aluminum oxide. They were having issues with inconsistent flatness values and very slow material removal rates. 

PROCESS: Engis 28FL230VP single-side lapping system with a HY Copper composite plate and 6(S1313-T4)STD-MA diamond slurry.  

RESULTS: Flatness of 2-3 lightbands was achieved in a single-step process, far exceeding the customer’s expectation. The stock removal rate of .00005” per minute provided a 5-15 minute cycle time and surface finish values of <1µ” were reached.

ENGIS  HYPREZ^®  ADVANTAGES:

Since 1938 the Engis Hyprez® brand name has been synonymous with high precision, high quality lapping systems.

Our goal then, as it is today, is to provide solutions to the most challenging surface finishing applications by offering customers unsurpassed expertise in diamond, including a full R&D department, unique diamond micronizing capabilities, and three process development laboratories. 

Engis diamond engineers can assist you in the proper selection of our specially formulated compounds and gels to match your application, operating parameters, and materials – Stainless Steel, Titanium, Inconel, Carbon Steel with Tungsten or Chromium Carbide Coatings.