Overview

This document details the PROMELTA* System, a precision grinding solution utilizing permanent magnetic chucks, electromagnetic chucks, vacuum chucks, and specialized magnetic blocks and controllers. It focuses on the PRB and PRC model series designed for high-accuracy grinding of various materials including nonmagnetic and small workpieces.

Product Models and Specifications

• Models: PRB-1218A, PRB-1530A, PRB-2050A, PRC-220B
• Dimensions: Provided in millimeters and inches, e.g., PRB-2050A measures 200 mm width with various length and height parameters.
• Electrical: PRC-220B operates at 3-phase 200 VAC, 50/60 Hz, 20A output current.
• Mass: Ranges from 14 kg (PRB-1218A) to 120 kg (PRC-220B controller).

Key Features

• Wide Material Compatibility: Suitable for nonmagnetic materials such as plastic, aluminum, stainless steel, ceramic, and glass, especially small workpieces that are difficult to hold with traditional magnetic chucks.
• High Grinding Accuracy: Achieves micron-level precision by using newly developed thin bonding films (workpiece fixing materials) that reduce thermal impact and maintain low temperature during securing and releasing.
• Reduced Workpiece Distortion: Eliminates warp caused by mechanical clamps, improving accuracy and stability.
• Durable Work Face: Made of iron for wear resistance and can be re-ground to restore accuracy.
• Easy Installation: Mountable via T-slots or directly on magnetic chucks due to iron mounting face.
• Compact Controller: Small footprint (450 mm x 450 mm x 845 mm) with remote operation capability.

Workpiece Fixing Materials

• Standard Type: High securing power with film thickness of 5-10 μm, melting temperature 65°C.
• Low-Viscosity (High Precision) Type: Lower securing power but ultra-thin film (1-2 μm), melting temperature 45°C, ideal for finishing operations.
• Material Holding Power: Varies by material; highest securing power on stainless steel (SUS304) and aluminum (A5056), lower on ceramics and plastics.

Operational Notes and Limitations

• Not suitable for abrasive-like surfaces (e.g., plaster), heavily warped workpieces (>0.5 mm), thin workpieces (<1.0 mm) prone to distortion from grinding heat, or certain resins like Teflon.
• Wax used in the system is sensitive to impact and unsuitable for cutting; dry operations may cause wax melting due to heat.
• Wet grinding operations are supported, enhancing versatility.

Comparison with Other Securing Methods

Grinding Accuracy Data

Test grinding results demonstrate the system's capability to achieve flatness and parallelism within 1-3 microns depending on material and fixing material type. Examples include:

• SKD steel (65x65x15 mm): 2 μm flatness per pass using diamond grinding wheel and low-viscosity fixing material.
• Cemented carbide (10x20x5 mm): 1 μm flatness and parallelism with diamond grinding wheel and low-viscosity fixing material.
• Ceramic alumina (50x50x10 mm): 2-3 μm accuracy with diamond grinding wheel.
• SUS304 stainless steel (φ72x20 mm): 1 μm flatness with standard fixing material.

Additional Accessories

• High-performance cleaner and optional microwave cleaner for removing residual fixing material after securing.

Summary

The PROMELTA* System offers a versatile, high-precision grinding solution for a wide range of materials, including challenging nonmagnetic and small workpieces. Its innovative fixing materials and temperature-controlled securing method minimize thermal and mechanical distortion, enabling micron-level grinding accuracy. The system is compact, easy to install, and supports wet grinding operations, making it suitable for advanced manufacturing environments requiring precision and reliability.