Traditional and modern surface

finishing
Internal Assessment 2

By:- Garima pandit

section:- K
What is traditional surface
finishing?

Traditional surface finishing refers to a

wide range of techniques used to modify
the surface of a material for functional or
aesthetic purposes. These techniques have
been around for centuries and have been
developed to work with a variety of
materials, including wood, metal, etc.
 Materials used in traditional
surface finishing
• Abrasives: These are the workhorses of mechanical finishing. Common
abrasives include:
Sand: Used in sandpaper, comes in various grits (coarseness) for
different levels of material removal.

Aluminum oxide: A versatile and widely used abrasive for grinding,

polishing, and sanding metals and other materials.

Diamond: The ultimate in abrasives, offering exceptional cutting

power and wear resistance for very hard materials.

• Chemicals:
Acids: Pickling metals to remove rust, scale
Bases: Specific cleaning applications on certain materials.

• Coating Materials:
Paints: Liquid suspensions of pigments and binders, offering
wide range of colors and finishes.
Powders: Dry powders used in powder coating, offering durable and
often colorful finishes.
 Techniques used in
traditional surface finishing
Mechanical Finishing:
Sanding: Rubbing the surface with sandpaper to smooth it out.
Grinding: Using a grinding wheel to remove large amounts of
material or create a rough texture.
Polishing: Utilizing polishing compounds and buffing wheels to
achieve a high shine.
Buffing: Bringing a high luster to the surface using a buffing wheel
and polishing compound.
Chemical Finishing:
Etching: Creating designs on metal surfaces using a controlled
chemical reaction.
Pickling: Cleaning metal surfaces by removing impurities with an
acid solution.
Anodizing: Electrolytically creating a protective oxide layer on metal
surfaces.
Painting: Applying a liquid paint for protection, decoration, or color
change.
 Advantages of traditional surface
finishing
Cost-effective: Many traditional methods are well-established
and require readily available tools and materials, making them
affordable for various applications.

Versatility: Traditional techniques can be applied to a wide

range of materials, from wood and metal to plastics and stone.

Proven Results: These methods have been around for

centuries and offer well-understood results in terms of
aesthetics, functionality, and performance.

Skill and Control: Traditional techniques often rely on skilled

craftspeople who can achieve a high level of control and
precision over the finishing process.

Repairability: Surfaces finished with traditional methods are

often easier and less expensive to repair compared to some
newer finishes.
Disadvantages of traditional surface finishing

Environmental Impact: Many processes use hazardous

materials. Chemical solutions in etching, pickling, and
electroplating can be harmful if not handled properly, requiring
special disposal procedures.

Health Concerns: Exposure to dust from sanding, grinding, and

blasting can pose respiratory risks. Additionally, some chemicals
used in these processes can be hazardous if inhaled or absorbed
through the skin.

Process Limitations: Certain techniques might not be suitable

for all materials or geometries. For example, intricate details
may be difficult to achieve with mechanical finishing techniques.

Safety Hazards: Working with power tools and abrasive

materials requires proper safety gear and precautions to avoid
injuries.

Time and Cost: Traditional techniques can be labor-intensive

and time-consuming, impacting production costs.
What is Modern surface
finishing?

Modern surface finishing builds on traditional

techniques but incorporates advancements in
technology and materials to address some of
the limitations and offer new possibilities.
Materials and techniques of modern surface finishing

Materials:

Biodegradable abrasives: Made from natural materials like corn cobs

or walnut shells for eco-friendly polishing and cleaning.

Cubic boron nitride (CBN): An extremely hard and wear-resistant

abrasive ideal for high-performance applications.

Diamond alternatives: Engineered abrasives offering similar cutting

power to diamond at a lower cost.

Water-based paints and coatings: Reduce VOC emissions and create a

healthier work environment.

Thermal spray powders: Diverse range of metal and ceramic powders

used in plasma spray coating for functional finishes.
.
Techniques
Advanced Ablation Techniques:

Laser ablation: Precise removal of material using a laser beam, ideal for
micromachining and intricate textures.
Waterjet cutting: High-pressure water stream with abrasive particles for
precise cutting and cleaning of various materials.
Electrochemical machining (ECM): Selective material removal using an electric
current and electrolyte solution, suited for complex geometries on conductive
materials.
Plasma Technologies:

Plasma spray coating: High-temperature plasma stream melts and propels

coating materials for strong bonds and wider material compatibility.
Atmospheric plasma treatment (APT): Modifies surface properties at
atmospheric pressure, improving adhesion, wettability, or surface activation
for further processing.
Robotic Automation:

Automated painting and coating systems: Ensure consistent application and

improve safety compared to manual methods.
Robotic polishing and buffing: Offers precise control and reduces human
exposure to dust and fumes.
Advantages of modern surface finishing
Environmental Benefits:
Reduced environmental impact:
Less hazardous materials are used, minimizing waste and hazards
associated with chemicals and solvents.
Water-based solutions and lower VOC coatings contribute to cleaner air.

Enhanced Efficiency and Performance:

Faster processing times: Automation and advanced techniques significantly
reduce processing times compared to traditional methods.

Safety Improvements:
Reduced worker exposure: Automation helps minimize worker exposure to
dust, fumes, and hazardous chemicals used in traditional methods.
Safer materials: Biodegradable abrasives and water-based coatings create
a healthier work environment.

Additional Advantages:
Cost-effectiveness: While some modern techniques might have a higher
upfront cost, the efficiency gains, reduced waste, and potentially longer
product lifespan can lead to overall cost savings.
Disadvantages of modern surface finishing
High Initial Investment: Advanced equipment like lasers, plasma torches, and
robotic systems can be expensive to set up, which might be a barrier for smaller
companies.

Complexity of Techniques: Operating and maintaining these advanced

technologies requires skilled personnel, adding to the overall cost and
complexity.

Limited Availability: Some of these techniques are still under development or

not widely adopted, making them less accessible for all applications.

Process Optimization Challenges: Integrating new techniques and materials

often requires extensive testing and process development to achieve optimal
results for a specific application.

Potential Safety Concerns: Plasma technologies and high-powered lasers involve

inherent safety hazards that require proper training and safety protocols.

Environmental Impact, Though Reduced: While generally more eco-friendly than

traditional methods, some modern techniques still generate waste or require
careful disposal of spent materials.
 Conclusion

In conclusion, modern surface finishing offers

significant advantages in terms of speed,
efficiency, environmental impact, and the
range of achievable effects. However,
traditional techniques may still be preferred
for certain applications where simplicity and
cost are the primary concerns.