Clamping, a major problem in the machining of advanced ceramic parts
October 16, 2023
The advanced ceramics market has experienced a significant increase in demand in recent years, with a forecast compound annual growth rate (CAGR) of 5.2% over the period 2023-2029
F-GRIP enables clean machining with increased clamping force without deforming or damaging the material and supports all operations in this process without affecting accuracy on all types of advanced ceramic parts
A promising future for the advanced ceramics market
The versatility, strength and unique properties of advanced ceramics have opened up a world of possibilities for applications in sectors such as aerospace, automotive and medical, among others. Unlike traditional ceramics, technical ceramics offer a unique combination of mechanical, thermal and chemical properties.
These materials are characterized by their exceptional resistance to corrosion, high temperatures and wear, making them ideal for demanding environments and high-performance applications. In addition, advanced ceramics offer excellent dimensional stability, low thermal conductivity and are electrically insulating, making them a versatile choice for a wide variety of industrial applications.
Thus, the advanced ceramics market has experienced a significant increase in demand due to its ability to meet the needs of industries seeking lightweight and durable materials. If in 2022 this market was valued at $10.9 billion, it is estimated to reach $15.56 billion by 2029, showing a compound annual growth rate (CAGR) of 5.2% during the forecast period (2023-2029), according to data from Maximize Market Research.
The automotive, medical and electronics industries are the most demanding for this material. In the automotive sector, it is used for battery, engine or bearing components due to its thermal and electrical qualities, while in the medical sector, an increase in demand for ceramics is expected for implant abutments, artificial bones and endosseous implants. In the electronics sector, technical ceramics are used because of their ability to provide electrical insulation, high temperature resistance, thermal stability and corrosion resistance, ideal for this type of application.
The advanced ceramics market is starred by various leading companies that have played a pivotal role in the development, research, production, and application of this material. Some of the major companies active in this market include globally renowned companies such as:
- Morgan Advanced Materials (UK)
- International Syalons(UK)
- 3M (US)
- Nishimura Advanced Ceramics Co., Ltd.(US)
- Ortech Advanced Ceramics(US)
- COI Ceramics, Inc.(US)
- Elan Technology(US)
- CoorsTek Inc.(US)
- Advanced Ceramics Manufacturing(US)
- Saint-Gobain Ceramic Materials(US)
- S&S Advance Ceramics(US)
- Momentive Technologies(US)
- STC Superior Technical Ceramics(US)
- Murata Manufacturing Co., Ltd.(Japan)
- AGC Ceramics Co., Ltd(Japan)
- KYOCERA Corporation(Japan)
- Paul Rauschert GmbH & Co. Kg.(Germany)
- CeramTec GmbH (Germany)
- BCE Special Ceramics GmbH(Germany)
- Bakony Technical Ceramics(Hungary)
Challenges in the machining of advanced ceramic parts
The manufacture of advanced ceramic parts is a complex process that requires high precision. However, the manufacture of ceramic components is not as cost-effective as the production of other materials such as metal or plastic. The machining process alone accounts for 80% of the cost of the part. In addition, the high hardness and abrasiveness of these parts present numerous difficulties when using conventional machining methods, often requiring the use of special abrasion-resistant tools (diamond tools) and machines that have to be completely customized.
One of the most notable obstacles is the inherent brittleness of many advanced ceramic parts. Although these parts often exhibit exceptional resistance to high temperatures and corrosive environments, they are often prone to break easily both in the machining process itself and in the prior clamping or fixturing stage. Conventional clamping systems such as the use of clamps, vacuum tables or magnetic tables are not entirely effective in many cases for machining ceramic parts.
This is why, in an attempt to find other alternatives, many companies dedicated to this type of manufacturing use adhesives or waxes to clamping their parts. These conventional adhesives or waxes do not achieve a sufficiently strong workholding in many occasions, which generates an increase of defective parts in production. In addition, they are sticky materials that are very difficult to remove from both the parts and the clamping tool, negatively affecting production and significantly increasing the price of the part.
F-GRIP: The solution for clean, efficient and versatile machining of advanced ceramic parts
F-GRIP is available in 200x200mm sheets in different thicknesses. This adhesive, patented and manufactured only by FRESMAK, provides super strong adhesion (1000-2000N/cm²) without deforming or damaging the material and withstands all machining operations without affecting precision. In addition, our super-strong adhesive peels off cleanly, avoiding extra cleaning operations. These features, combined in a single clamping system, represent a significant advantage over conventional clamping systems.
Another advantage is its ability to adapt to specific parts because it can be cut to any desired shape. The elastomeric composition of F-GRIP is ideal for clamping non-flat surfaces, porous materials or parts with a small or limited clamping surface with an accuracy of up to 2 microns.
It is applied with simultaneous temperature (up to 150 ºC) and pressing (~ 1 Kg per cm2 of adhesive). Subsequently, the super-strong bond between the part and the base is generated when cooled to 25-30ºC and, after machining, the part can be demolded by heating up to 80ºC, with easy and clean removal. In addition, F-GRIP recovers its initial shape by applying heat and can be reused for another operation.
Thus, with our super-strong and removable adhesive clamping, a single type of clamping system is used for machining all types of advanced ceramic materials and parts (alumina, zirconia, silicon carbide and nitride, glass, quartz, macor or boron nitride).
We know you will be surprised by its efficiency, so we will let you try it. Contact us now and request a sample.
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