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Unit-4-Part 2-Micro and Superfinishing methods

The document discusses various surface finishing methods, including lapping, honing, super finishing, and burnishing, highlighting their importance in improving product performance and aesthetics. Each method is described in terms of processes, advantages, and applications, with specific details on tolerances and roughness levels. The document emphasizes the significance of achieving high-quality surfaces to enhance durability and reduce wear in mechanical components.

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Jaydip Parmar
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
8 views

Unit-4-Part 2-Micro and Superfinishing methods

The document discusses various surface finishing methods, including lapping, honing, super finishing, and burnishing, highlighting their importance in improving product performance and aesthetics. Each method is described in terms of processes, advantages, and applications, with specific details on tolerances and roughness levels. The document emphasizes the significance of achieving high-quality surfaces to enhance durability and reduce wear in mechanical components.

Uploaded by

Jaydip Parmar
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Micro and Super Finishing

Methods
Introduction

 A surface is defined as the topmost layer of an object which


interacts with the surrounding
 Quality of surface is a factor which determines the performance of
a manufactured product
 Most of the interactions between mechanical components happen
at the surface level
Why?

 Safety, smooth surfaces are free from scratches and sharp corners
 Reduced friction and wear, increased durability
 Good quality surface provides better mechanical and physical
properties
 Aesthetic appeal
Surface Finishing Processes

 Process for good surface finish are honing, lapping, burnishing and
super finishing

Processes Tolerance(mm) Roughness(µm)


Grinding ±0.008 5 to 75
Lapping ±0.005 2 to 15
Honing ±0.005 4 to 30
Super Finishing ±0.003 1 to 10
Lapping

 Oldest method of obtaining fine finish.


 Machining process in which two surfaces are rubbed together with
abrasive between them
 Can be done in two ways:- by hand movement or by using machine
 To accomplish the process, lapping plate is rotated so that work
piece is rubbed against lapping plate to obtain good surface finish.
 Material removal ranges from .003 to .03mm
Lapping Machine
Principle of Machine Lapping

 This process uses a lapping plate and conditional rings.


 Conditional rings provide sits for work piece.
 This rings rotate and rubbed the work piece against lapping plate.
Abrasive particles are provided with suitable medium like liquid or
in powder form. This rubbing removes metal in form of microchips
and provide super finishing.
Manual Lapping

 In hand lapping process, the work piece is rubbed over the lapping
plate manually.

 In this process first the plate is coated with the abrasive material
which in in the form of paste. Now the work piece is rubbed over
plate by applying a small pressure manually.
Abrasives of Lapping
Al2O3
Cr2O3
Diamond
Lubricating Materials of Lapping
Machine oil and Grease
Advantages Of Lapping

 Improves surface finish by eliminating the peaks and valleys.


 No heat generation and thermal damage
 Improves service life of the moving parts which are subject to wear.
 An extremely high accuracy of form and dimensions and a good
surface quality are obtained.
Honing

 Honing is a smoothing process where a tool (hone) carries out a


rotary motion and reciprocating motion.
 Workpiece is stationary
 Gives us accurate holes to within ± 0.025 mm in diameter

Workpiece Honing Stick


Spring Pressure

Abrasive contact of tool Rotating + reciprocating shaft


with workpiece
Characteristics of Honing

 Larger no. of grains (100 times greater than that of grinding)


 Cutting speed is 1/50-1/150 of grinding speed
 Achieve better surface quality (smooth surface) and obtain high
dimensional accuracy
 Material removal rate is relatively high as compared to grinding
lo1
Hl

Hs
WORK
l

Hl
lo2

l is the workpiece length in mm Sufficient length of HS for honing entire


Hl is the hone length (1.5–1500 mm)
lo1 is the hone upper overrun in mm length of hole:
lo2 is the hone lower overrun in mm
Hs is the stroke length Hs = l − Hl + lo1 + lo2
Honing Kinematics
N : the uniform rotational speed
Fr : frequency of reciprocating motion

Peripheral speed : Vp = ПdN

Linear feed speed : St = 2 Hs Fr

Cutting speed :

Cross hatch angle :

tan α = reciprocating speed (m/min)


rotating speed (m/min)
 Abrasive materials used for honing

• SiC for honing cast iron and non ferrous materials


• Al2O3 for honing of steels
• Diamond for chrome plated, hard carbide and
ceramics

 Honing fluid

• sulfurized material mixed with kerosene.


• Flushes workpiece metal and abrasive particles
from stone
• act as coolant
• act as lubricant
Honing Tools
Parameter that affect performance of honing

Effect of time on removal rate

Removal rate is
hyperbolic.
Due to wear, burning
and surface scratching
occur which increases
roughness
Effect of unit Pressure Effect of Speed

Between 1MPa-3.2 MPa. Higher speeds produce fine surface finish


Material removal rate increase and raise the removal rate but it decreases
with unit pressure but the dimensional accuracy, overheats the
deteriorates surface roughness. workpiece, and dulls the abrasives.
Applications
 Cylindrical and tapered surfaces
 External surfaces in the form of cylinders and cones
 In wide ranges of hole, i.e. 3 mm to 1000 mm.
 Finishing of cylinders for IC engines
 Gears

Gear Honing Engine cylinder honing


Super Finishing

 Also known as micro honing, micro stoning, micro finishing, super


finish honing and short stroke honing.
 Similar process to honing.
 Produces very low surface roughness average(Ra) down to about 2
to 4 microns.
 Time need for super finishing is very short.
 Within 50 seconds workpiece is super finished to a roughness of
0.075µm.
 Uses bonded abrasive stick moved with a reciprocating motion and
pressed against the surface to be finished.
 Typically a single fine grit stone is rubbed at high frequencies and
small amplitudes.
 The stone is rotated over the component while the component is
spun in the opposite direction.
 Cutting fluid is used to cool the tool workpiece interface, also helps
wash away the tiny chips produced.
Honing v/s Superfinishing

 Cannot change geometry as well as honing due to the low material


removal rate.
 Stroke length is much shorter but frequency is larger(Up to 1500
strokes/min).
 Lower pressure applied.
 Feed given to workpiece and feed rate is smaller.
 Grit size is smaller than that is used with honing.
 Produces lower roughness average with limited material removal.
Applications

 Sewing machine parts


 Automotive cylinders
 Bearing components
 Piston rods
 Axles
 Shafts
 Fuel injector components
Advantages and Disadvantages

 Increased part life


 Decreases wear
 Closer tolerance

 The main disadvantage of Super finishing process is that it requires


a hard turning process before hand, which increases cost.
Burnishing

 Cold working process


 Surface layer of a work piece is plastically deformed due to rubbing
action with a hard tool: either roller or sliding ball
Working
 Surface of a machined part has a profile composed of alternating
irregular peaks and valleys
 When a burnishing tool is pressed onto the surface it forces the
material of the peaks to flow to the valleys and fills them
 As a result the surface finish is improved
 There exist residual compressive stresses which produces a stress
hardened layer
 Prevents formation of cracks that lead to fatigue failure
 Tools are generally made out of high speed steel or carbide material
 Positioned in slots along with a cage
 Contains numerous tapered and polished rollers
 Mandrel is used for rotating the rollers
Benefits
 Simple and highly productive, mirror finish in one pass
 Can be carried out on any conventional machines like lathe and CNC
machine
 Requires low energy and torque since pressure load is relatively low:
commonly 4.5-45 kgf
 Does not produce chips, shavings, fillings, turnings or dust
 Burnishing tools wear slowly, long tool life
 Improved metallurgical properties
 Low operator skill required
 Surface hardness of Steels and cast irons may be increased by 2x and
aluminum alloys by 20%
Applications

 Steels  Aluminum Alloys


• Shafts • Aircraft fittings
• Press rods • Truck wheel
• Connecting rods • Brake discs
• Valve guides • Hydraulic pistons
• Bearing housing • Pneumatic cylinder
• Rocker arm • Hinge pins
THANK YOU!

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