Method for frictionally guiding and forming ferrous metal

Abstract

The present invention is a method for frictionally guiding and forming ferrous metal using a tool having a polycrystalline diamond ("PCD") surface in such a manner so as to limit graphitization, dissolution, and diffusion of the PCD surface caused by the ferrous metal. A tool having a PCD surface, such as a rail punch used to form stainless steel rail wipers in head suspensions, a dimple punch socket used to form dimples in head suspensions, or a frictional guide surface used to engage and mount base plates to head suspension load beams, engages and is frictionally moved relative to an object of ferrous metal. In some applications, the tool is further used to plastically deform the ferrous metal. This engagement, movement, and deformation occurs under conditions which limit asperity and surface temperatures of the PCD surface and the ferrous metal to about 50 degrees Celsius and about 700 degrees Celsius, respectively. This is accomplished by minimizing the force required to form the metal, and by limiting the speed at which the formation occurs.

Dependencies are inferred from the claim text.