Professional Documents
Culture Documents
Surface Finishing Processes - Manufacturing Processes-II
Surface Finishing Processes - Manufacturing Processes-II
Honing tool
Honing
Abrasive process performed by a set of bonded abrasive
sticks using a combination of rotational and oscillatory
motions
Common application is to finish the bores of internal
combustion engines
Grit number (grain size) range between 30 (medium) and 600
(very fine) (the smaller grain size, the larger grit number)
Surface finishes of 0.12 m (5 -in) or better
Creates a characteristic cross-hatched surface that retains
lubrication
Honing
Figure 25.16 The honing process: (a) the honing tool used for internal bore surface,
and (b) cross-hatched surface pattern created by the action of the honing tool.
Honing Tool
Rotation speed
Oscillation speed
Parameters that affect material removal rate (MRR) and surface roughness (R) are:
Unit pressure, p
Honing time, T
Lapping
Lapping
Lapping
In lapping, instead of a bonded abrasive tool, oil-based fluid suspension of
very small free abrasive grains (aluminum oxide and silicon carbide, with
typical grit sizes between 300 and 600) called a lapping compound is applied
between the work piece and the lapping tool.
The lapping tool is called a lap, which is made of soft materials like copper,
lead or wood. The lap has the reverse of the desired shape of the work part.
To accomplish the process, the lap is pressed against the work and moved
back and forth over the surface.
Lapping is sometimes performed by hand, but lapping machines accomplish
the process with greater consistency and efficiency.
Lapping
Lapping
Lapping is regarded as the oldest method of obtaining a fine finish.
Lapping is basically an abrasive process in which loose abrasives function
as cutting points finding momentary support from the laps. Material
removal in lapping usually ranges from .003 to .03 mm but many reach
0.08 to 0.1mm in certain cases.
The cutting mechanism in lapping is that the abrasives become embedded
in the lap surface, and the cutting action is very similar to grinding, but a
concurrent cutting action of the free abrasive particles in the fluid cannot be
excluded.
Lapping is used lo produce optical lenses, metallic bearing surfaces, gages,
and other parts requiring very good finishes and extreme accuracy.
Lapping
Characteristics of lapping process:
Usually lap and work piece are not positively driven but are guided in
contact with each other
Relative motion between the lap and the work should change continuously
so that path of the abrasive grains of the lap is not repeated on the work
piece.
Lapping
Uses fluid suspension of very small abrasive particles between
workpiece and lap (tool)
Lapping compound (fluid suspension) - fluid with abrasives,
general appearance of a chalky paste
Typical grit sizes (Grit number) between 300 (medium) to 600
(very fine)
Applications: optical lenses, metallic bearing surfaces, gages
The same as polishing samples for microscopic or electronic
microscopic tests
Lapping
Schematics of lapping process showing the lap and the cutting action of suspended
abrasive particles.
Lapping
Lapping
Figure (a) Schematic illustration of the lapping process. (b) Production lapping on
flat surfaces.(c) Production lapping on cylindrical surfaces.
Lapping
Abrasives of lapping
Al2O3 and SiC, grain size 5~100m
Cr2O3, grain size 1~2 m
B4C3, grain size 5-60 m
Diamond, grain size 0.5~5 V
Lubricating materials of lapping
Machine oil
Rape oil
grease
Technical parameters affecting lapping processes are
unit pressure
the grain size of abrasive
concentration of abrasive in the vehicle
lapping speed
Buffing
Buffing
Polishing
Polishing is a finishing operation to improve the surface finish by means of a
polishing wheel made of fabrics or leather and rotating at high speed. The abrasive
grains are glued to the outside periphery of the polishing wheel. Polishing operations
are often accomplished manually.
Buffing
Buffing is a finishing operation similar to polishing, in which abrasive grains are not
glued to the wheel but are contained in a buffing compound that is pressed into the
outside surface of the buffing wheel while it rotates. As in polishing, the abrasive
particles must be periodically replenished.
As in polishing, buffing is usually done manually, although machines have been
designed to perform the process automatically.
Buffing wheels are made of discs of linen, cotton, broad cloth and canvas
Buffing
Buffing
Super Finishing
Super Finishing
Super finishing
The process consists of removing chatter marks and fragmented or smear metal from
the surface of dimensionally finished parts. As much as 0.03 to 0.05 mm of stock can
be efficiently removed with some production applications, the process becomes most
economical if the metal removal is limited to 0.005 mm
Super Finishing
Similar to honing - uses bonded abrasive stick pressed
against surface and reciprocating motion
Differences with honing:
Shorter strokes
Higher frequencies
Lower pressures between tool and surface
Smaller grit sizes
Super Finishing
Figure Schematic illustrations of the super finishing process for a cylindrical part. (a)
Cylindrical mircohoning, (b) Centerless microhoning.
Surface Treatment
Introduction
Surface Treatments
Why?
Type
Why use a surface treatment?
Improves durability
Controls Friction
Reduces Adhesion
Why use surface treatment?
Improves Lubrication
Rebuild Surfaces
Aesthetics
Types of Treatments
Mechanical Surface Treatments
Mechanical Plating & Cladding
Case Hardening
Thermal Spraying
Vapor Deposition
Laser Treatments
Mechanical Surface Treatments
Peening
Shot Peening
Laser Shot Peening
Water-jet Peening
Ultrasonic Peening
Roller Burnishing
Explosive Hardening
Mechanical Plating & Cladding
Mechanical Plating
Cladding
Laser Cladding
Case Hardening and Hard Facing
Case Hardening
Hard Facing
Spark Hardening
Thermal Spraying
Combustion Spraying
Thermal Metal-Powder
Spray
Plasma Spray
Vapor Deposition
Physical Vapor Deposition
Vacuum Deposition
Sputtering
Chemical Deposition
Ion Platting
Physical Vapor Deposition
Sputtering
Chemical Vapor Deposition
Thermochemical Process
Cutting Tools
Thicker
Tedious
Ion Implantation & Diffusion
Coating
Particulates penetrate substrate
Masking capability
Laser Treatments
Heating
Melting
Vaporization
Peening
Electroplating, Electroless Plating,
and Electroforming
Electroplating
Workpiece (cathode) is
plated with other metal
(anode) through a water-
based electrolytic solution
A SLOW Process!!!
75 micrometers/hour
Solution must be replenished
Sacrificial anode
Additional salts of metal
Electroplating, Electroless Plating,
and Electroforming
Operation Sequence
Chemical Cleaning
Acid Bath
Application of a Base Coat
(Optional)
Final Electroplating
Rinse Tanks
Electroless Plating
Chemical Reaction
More Expensive $$
Uniform Thickness
Electroforming
Metal-fabrication
Metal electrodeposited on a
mandrel
Conversion Coatings
Anodizing-
The workpiece is the
anode in an electrolytic
cell
Coloring-
Alters color of metals,
alloys, and ceramics
Conversion of surfaces
into chemical
compounds: oxides,
chromates, and
phosphates
Hot Dipping
Workpiece is dipped into
molten metal
Zinc- galvanized-steel sheet
Tin- food containers
Paint Classification
Enamels
Lacquers
Water-based paints
What is Galvanizing?
The process of
galvanizing consists
of coating metals,
such as iron, with a
thin protective layer of
zinc.
The zinc layer
provides protection to
Before & After the metal from
Hot Dip Galvanizing
corrosion.
Cathodic Protection
*
*