Using a Novel Floating Grinding Process to Improve the Surface Roughness Parameter of a Magnetic Head

This work concentrated on the improvement of the surface roughness of a magnetic head, through the use of an ultrafine nanodiamond slurry, and a novel floating grinding process, which optimize different experimental factors required for the fine grinding of a magnetic head. The preparation of the grinding plate was confirmed by the observation of the surface change, depth detection, and flatness after ultrafine nanodiamonds were embedded into it by a Keyence high-power microscope at a 20 K magnification. The flatness was measured by a TOTO instrument. The optimum conditions were found to be a pit ratio reach of 30:70 and a plate flatness (average) of 1.8 μm. The rotation speed and vibration frequency were 0.3 and 10 rpm, respectively, for the grinding process. The morphology, size, and elemental composition of blackspots were investigated by SEM, AES, AFM, and transmission electron microscopy (TEM) analysis, which showed that the diameter of the diamonds in the slurry was important for grinding surface improvement. A novel method was proposed in this study to fine grind a magnetic head using a small-sized diamond slurry (100 nm) in conjunction with a novel float lapping method. Comparison experiments were performed under both normal conditions and improved conditions. The results show that by using the novel float lapping method with a small-sized diamond slurry, the minimum roughness was obtained. The finest roughness obtained for the slider surface reached 0.165 nm without blackspots or scratches

Investigation and Improvement Strategies for Mold Fracture: A Study on the Application of a Pulse Electrodeposition Method for Enhancing Mold Lifespan

An investigation on the fracture of a mold, comparing it with a normal part using specific techniques, such as EDX, SEM, and AES, is presented in this study. The EDX analysis revealed that the composition of the normal part was consistent with that of low-carbon steel, mainly comprising Fe and C. In contrast, the fractured part exhibited cracks due to nonconforming nonmetallic inclusions and reticular carbides, with fractures resulting from microporosity agglomeration and cleavage fracture. The SEM and AES analyses further presented the causes of mold fracture, highlighting the mechanism by which the dimples on the specimen edge contributed to the fracture. The EDX analysis confirmed that the mold experienced thermal brittleness during use. To enhance mold durability and extend its lifespan, a pulse electrodeposition method was employed to create a NiCo alloy coating as a replacement for the Cr layer on the metal surface. The coating exhibited a smooth and scratch-free surface. The prepared NiCo special coating significantly increased the mold yield strength by approximately 313.8%, facilitated a 13% increase in plastic deformation, and reduced the fracture strain by 25%, effectively preventing mold fracture and improving its service life