Ferrite is an inorganic material made by mixing iron oxide with various metallic elements, including nickel, zinc, or barium. The result is a magnetized ceramic component that is often used in speakers, transformers, and more. Ferrite can be a difficult material to process without the right equipment due to its magnetic characteristics. At Quartzite Processing, Inc., we offer ferrite machining services in which we purchase molded ferrite materials and grind them to create parts for a wide range of industries, including millimeter-wave ferrites for millimeter-wave technology.
Grinding Methods and Process
We offer a wide variety of processes to produce the precise ferrite shapes you require for your application:
Inside diameter grinding removes material from the inside of a conical or cylindrical workpiece. At Quartzite Processing, we can use I.D. grinding on components with dimensions ranging from 0.030″ to 12″.
Outside diameter grinding is another cylindrical process that removes material from the outside of cylindrical workpieces with dimensions of 0.025″ to 14″.
This type of ferrite milling involves placing a workpiece between two wheels, one of which is fixed while the other holds and turns the workpiece. This method is commonly used to create tapered, hourglass, or other complex shapes. Centerless grinding has three feed methods:
- Through-Feed: Best for cylindrical parts, the regulating wheel pulls the material in, which means no additional feeding mechanism is typically required.
- End-Feed: Ideal for tapered components, the workpiece is fed through the grinder until it reaches a stop at which point it reverses.
- In-Feed: This manual process is ideal for hourglass and other unusual shapes. The workpiece is fed into the grinder by hand and is carefully monitored and adjusted to achieve the desired contours.
The ferrite grinding wheel essentially sands the workpiece to create a smooth, flat surface. This is a common finishing process, and it can be used to achieve varying degrees of smoothness, depending upon the material and how abrasive the grinding wheel is.
Honing is a form of I.D. grinding used to create a precise specific finish or shape on the inside of the workpiece. It’s typically done by machine, but it can be a manual process for prototypes or small-scale production.
Using abrasive particles and ultrasonic vibration, this process slowly wears away at the material to create holes and other shapes. Also referred to as ultrasonic machining, this process doesn’t use any heat or chemicals, preventing the material from having to endure excessive stress, allowing for a stronger, more durable finished product.
By dressing the grinding wheel with the desired profile, you can achieve specific form and geometry tolerances. There are various dressing methods, depending upon your budget and the desired shape of the finished product. These include profile rolls, forming rolls, and profile diamonds. While profile rolls are the most expensive to produce, they’re durable, creating the most cost-efficient solutions for large production runs. Forming rolls cost less upfront but must be replaced more often.
In this specialized type of cylindrical grinding, the grinding wheel is the same shape as the finished product and uses a disc wheel to grind both sides of the workpiece simultaneously.
At Quartzite Processing, Inc., we use a variety of grinding methods, depending upon your desired outcome. All of our work is done in a climate-controlled space by expert machinists who measure, check, and recheck every component to ensure we deliver precise results to meet or exceed your expectations.
Uses of Ferrite
There are two types of ferrite: hard and soft. They each have advantages in specific applications.
- Soft Ferrite: Soft ferrite is best suited for use in inductors, transformers, antennas, magnetic audio heads, electronic data processing equipment, microwaves, and more.
- Hard Ferrite: Hard ferrite is ideal for industrial electronics, sensor technology, household appliances, radios and loudspeakers, clocks, direct current motor rotors, and more.
The Quartzite Processing Advantage
As a family-owned business with a history of excellence reaching back to the 1950s, we have the experience, facilities, equipment, and highly-trained machinists required for ferrite sintering in superfine sizes and tolerances. We carry a massive stock of material inventory and can provide rapid turnarounds, with most jobs being completed and shipped within a week. we specialize in Ship-to-Stock and Just-in-Time Delivery. Our ISO 9001:2015 and ITAR certifications demonstrate our commitment to quality, safety, and customer satisfaction. Contact us to learn more about machining ferrite magnets or request a quote for your project today.