1 Finishing Operation

Introduction:

The objective of finishing operation is to achieve superior surface finish up to mirror-like

finishing and very close dimensional precision. The finishing operations are assigned as
the last operations in the single part production cycle usually after the conventional or
abrasive machining operations, but also after net shape processes such as powder
metallurgy.

The finishing processes discussed in this section include grinding, honing, lapping, super-
finishing, polishing, and buffing.
2 Finishing Operation

1.1 Grinding

Grinding is a material removal process in which abrasive particles are contained in a bonded
grinding wheel that operates at very high surface speeds. The grinding wheel is usually disk
shaped and is precisely balanced for high rotational speeds. The geometry of grinding is shown
in the figure:
3 Finishing Operation
The abrasive materials of greatest commercial importance today are listed in the table:

1.1.1 Wheel grade

Wheel grade indicates the wheel bond strength. It is measured on a scale ranging from soft to
hard. Soft wheels loose grains easily and are used for low material removal rates and grinding of
hard materials. Harder grades are preferred for high productivity and grinding of relatively soft
materials.

1.1.2 Structure
The wheel structure indicates spacing of the abrasive grains in the wheel. It is measured on a
scale that ranges from open to dense. Open structure means more pores and fewer grains per unit
wheel volume, and vice versa. Open structure is recommended for work materials that tend to
produce continuous chips, while denser structure is used for better surface finish and dimensional
precision.

1.1.3 Grinding wheel specification

Grinding wheels are marked with a standardized system of letters and numbers, which specifies
the parameters of the grinding wheel. Grinding wheels are available in a variety of shapes and
sizes the most popular shown in the figure:
4 Finishing Operation

1.1.4 Grinding operations

a. Surface grinding
Surface grinding is an abrasive machining process in which the grinding wheel removes material
from the plain flat surfaces of the workpiece. In surface grinding, the spindle position is either
horizontal or vertical, and the relative motion of the workpiece is achieved either by
reciprocating the workpiece past the wheel or by rotating it. The possible combinations of
spindle orientations and workpiece motions yield four types of surface grinding processes
illustrated in the figure:
5 Finishing Operation

b. Cylindrical grinding
In this operation, the external or internal cylindrical surface of a workpiece is ground. In external
cylindrical grinding the workpiece rotates and reciprocates along its axis, although for large and
long workparts the grinding wheel reciprocates. In internal cylindrical grinding, a small wheel
grinds the inside diameter of the part. The workpiece is held in a rotating chuck in the headstock
and the wheel rotates at very high rotational speed. In this operation, the workpiece rotates and
the grinding wheel reciprocates.

c. Centerless grinding
Centerless grinding is a process for continuously grinding cylindrical surfaces in which the
workpiece is supported not by centers or chucks but by a rest blade. The workpiece is ground
between two wheels. The larger grinding wheel does grinding, while the smaller regulating
wheel, which is tilted at an angle i, regulates the velocity V f of the axial movement of the
workpiece.
6 Finishing Operation

d. Creep-feed grinding
Grinding has traditionally been associated with small rates of material removal and finishing
operations. However, grinding can also be used for large-scale metal removal operations similar
to milling, shaping, and planing. In creep-feed grinding, the depth of cut d is as much as 6mm,
and the workpiece speed is low. The wheels are mostly softer grade resin bonded with open
structure to keep temperatures low. Creep-feed grinding can be economical for specific
applications, such as grinding cavities, grooves, etc.
7 Finishing Operation

1.2 Honing

Honing is a finishing process performed by a honing tool, which contains a set of three to
a dozen and more bonded abrasive sticks. The sticks are equally spaced about the
periphery of the honing tool. They are held against the work surface with controlled light
pressure, usually exercised by small springs. The honing tool is given a complex rotational
and oscillatory axial motion, which combine to produce a crosshatched lay pattern of very
low surface roughness:

In addition to the surface finish of about 0.1 µm, honing produces a characteristic
crosshatched surface that tends to retain lubrication during operation of the component,
thus contributing to its function and service life. A cutting fluid must be used in honing to
cool and lubricate the tool and to help remove the chips.

A common application of honing is to finish the holes. Typical examples include bores of
internal combustion engines, bearings, hydraulic cylinders, and gun barrels.
8 Finishing Operation

1.3 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.

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 to produce optical lenses, metallic bearing surfaces, gages, and other parts
requiring very good finishes and extreme accuracy.
9 Finishing Operation

1.4 Super-finishing

Super-finishing is a finishing operation similar to honing, but it involves the use of a single
abrasive stick. The reciprocating motion of the stick is performed at higher frequency and
smaller amplitudes. Also, the grit size and pressures applied on the abrasive stick are smaller. A
cutting fluid is used to cool the work surface and wash away chips.

1.5 Polishing and buffing

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 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.
10 Finishing Operation

Polishing is used to remove scratches and to smooth rough surfaces while buffing is used to
provide attractive surfaces with high luster.