Abrasive Machining Processes: Material Removal Processes Involving Interaction of Abrasive Grits with the Workpiece at Relatively Higher

Speeds and Shallow Penetration Depth

FINISHING and SUPER-FINISHING OPERATIONS

Oldest, Most Important, and Essential of the Basic Machining Processes Abrasives Natural Abrasives:- Sand, Emery, Garnets, Corundum, Diamond, Quartz, Artificial Abrasives:- Al2O3, SiC, Si3N4, CBN, Boron Carbide, Poly-Crystalline Diamond (PCD), etc. Two Unique Features Each Cutting Edge is Very Small and Many Cutting Edges can Cut Simultaneously Very Fine Cuts are Possible Better Surface Finish and Dimensional Tolerance Extremely Hard Abrasive Grits can be Produced Very Hard Work Materials can be Machined
Finishing and Super Finishing Processes
Dr. Neelesh K. Jain

Abrasive Machining Processes

Process Grinding Particle Mounting Bonded Wheel Surface Roughness (m) 0.4 1.6 (For Medium Grit Size) 0.2 0.4 (For Fine Grit Size) Features Uses Wheels with Short Cutting Arc; Accurate Sizing; Finishing; Low MRR; Can be done at High Speed (12,000 sfpm) Uses Wheels with Long Cutting Arc; Very Slow Feed Rate; Large Depth of Cut High MRR; Rough Rapid Technique to Clean up and Deburr Castings and Forgings 0.1 0.8 0.0125 0.2 Free in Suspension Free Abrasives in Jet 0.025 0.4 Uses Fine Abrasive Particles Embedded in a Soft Metal or Cloth Primarily a Surface-Finishing Process Very High-Velocity Water Jet Carries the Abrasive Particles Uses Stones Containing Fine Abrasives; Primarily a Hole-Finishing Process

Creep Feed Grinding Snagging (Rough Grinding of Castings) Honing Superfinishing Lapping

Bonded Open, Soft

Bonded Belt

Bonded Sticks

Abrasive Water Jet

0.2 0.8

Finishing and Super Finishing Processes

Dr. Neelesh K. Jain

Abrasive Finishing Processes Finishing Process Honing Usual Part Geometry Circular Hole (i.e. Cylinders, Bearings, Gun Barrel, ) (Has been tried for Gear and External Surfaces also) Flat Surfaces; External Cylindrical Surfaces Flat Surfaces, Slightly Spherical Surfaces (i.e. Lens) Miscellaneous Shapes Miscellaneous Shapes Shafts, Gears, Springs, Connecting Rod, Turbine/Compressor Blades, Flat Surfaces, etc. Surface Roughness (m) 0.1 0.8 Dimensional Tolerance (m) 2.5 m

Superfinishing Lapping Polishing Buffing Peening Burnishing

0.0125 0.2 0.025 0.4 0.025 0.8 0.0125 0.4

0.4 m 0.4 m m m m

Internal and External Flat, Cylindrical, and m Conical Surfaces MASS Finishing Processes: Finishing of Parts in Bulk by a Mixing Action Inside a Container Usually in the Presence of an Abrasive Media Examples: Tumbling, Vibratory Finishing Usually Used for Small Parts that are Uneconomical to Finish Individually Used for Stampings, Castings, Forgings, Extrusions, and Machined Parts Also Used for Cleaning, Deburring, Descaling, Deflashing, Polishing, Radiusing, and Burnishing
Finishing and Super Finishing Processes
Dr. Neelesh K. Jain

[1] HONING
A Finishing Process that Uses Fine Bonded Abrasive Stones to Remove Very Small Amount of Material Honing Tool Consists of a Set of Al2O3 and SiC Bonded Abrasives, called Honing Stones or Sticks Mounted on a Mandrel Two to Four Sticks for Small-Holes and Dozen or More for Large-Holes Honing Stones Differs from the Grinding Wheel in that Additional Materials such Sulfur, Resin, Wax are Added to the Bonding Agent to Modify the Cutting Action Honing Tool or Head is Given a Motion that is Combination of Rotation and Linear Reciprocation, Regulated in such a Way that a Given Point on the Honing Stick does NOT Trace the Same Path Repeatedly Such Motion of the Honing Tool Produces a Characteristic Cross-Hatched Surface that Tends to Retain Lubrication during the Operation of the Component The Stones can be Adjusted Radially for Different Hole Sizes Length of the Motion (or Stroke Length) should be such that Honing Stones/Sticks Extend Beyond the Work Surface at the End of Each Stroke
Finishing and Super Finishing Processes
Dr. Neelesh K. Jain

Cutting Speed is Much Lower than that of Grinding A Cutting Fluid is Used to Remove Chips and Keep Temperature Low Fineness of the Surface Finish can be Controlled by Type and Size of Abrasives Used Honing Pressure Applied Rotational Speed Vr Oscillation Speed Vo Length and Position of Stroke Same Trade-off Between Finish and MRR Exists in MRR as in Grinding Honing Parameter Surface Roughness Value Dimensional Tolerance Abrasive Grit Size
Type of Abrasive Conventional Abrasives

Value or Range 0.1 0.8 m 2.5 7.5 m 80 600

Diamond Cubic Boron Nitride (CBN)

Honing Speed, Vc (m/min) Honing Pressure, Ps (N/mm2)

High MRR Best Quality Service High MRR Best Quality Service

20 30 5 30

40 70 40 70

35 90 20 60

12 0.5 1.5

28 13

24 12

Material Removed 0.125 - 0.5 mm If Honing Parameters are Not Controlled Properly then it can Generate Bell-Mounted, Tapered, Barrel-Shaped, and Wavy Holes
Finishing and Super Finishing Processes
Dr. Neelesh K. Jain

HONING MACHINE Single and Multiple Spindle Machine Available in Both Horizontal and Vertical Types Honing Machines can be Equipped with Sensitive Measuring Devices that Collapses the Honing Head when the Desired Size has been Reached For Honing Single, Small Internal Cylindrical Surfaces, the Workpiece is Manually Held and Reciprocated Over a Rotating Hone If Volume of Work is Sufficient then Honing is an Inexpensive

APPLICATIONS: Used to Size and Finish Bored Holes i.e. Finishing of I.C. Engine Cylinders, Hydraulic Cylinders, Bearings, Gun Barrels Honing Enlarges and Finishes a Hole but cannot Change its Location To Remove Common Errors Left by Boring: Taper, Out-of-Roundness, Waviness, Tool Marks Honing has been also Tried for Finishing of External Cylindrical and Flat Surfaces, Gears To Remove Sharp Edges of Cutting Tools and Inserts and Finishing the Face of Cutting Tools

Finishing and Super Finishing Processes

Dr. Neelesh K. Jain

[2] SUPERFINISHING
A Variation of Honing that is Typically Used on Flat and Cylindrical Surfaces. Superfinishing Also Uses a Bonded Stick Moved with a Reciprocating Motion and Pressed Against the Surface to be Polished How Superfinishing Differs from the Honing Process ? Uses Very Light Controlled Pressure (0.07 to 0.28 N/mm2) Rapid (Over 400 Cycles per Minute) Short Stroke (Less than 6.25 mm) Lower Workpiece Speed (Less than 15 m/min) Smaller Size of Abrasive Grits (up to 1000) Relative Motion Between the Abrasive Stick and Work Surface is Varied so that an Individual Grit Never Traverses the Same Path Twice A Low-Viscosity Lubricant-Coolant Flooded Over the Work Surface Separate the Abrasive Stick from the Work Surface Surface Roughness < 1 m

Finishing and Super Finishing Processes

Dr. Neelesh K. Jain

Superfinishing is Based on the Phenomenon that A Lubricant of a Given Viscosity will Establish and Maintain a Separating Lubricating Film Between Two Mating Surfaces if their Roughness does Not Exceed a Certain Value and if a Certain Critical Pressure, Holding Them Apart, is Not Exceeded Consequently Minutes Peaks on the Surface are Cut Away by the Honing Stone Applied with Controlled Pressure and a Certain Degree of Smoothness is Achieved When Lubricant Establishes a Continuous Film Between the Stone and Workpiece and Separate them then No Further Cutting Action Occurs For a Given Pressure, Lubricant, and Honing Stone, Each Workpiece is Honed to the Same Degree of Smoothness

Finishing and Super Finishing Processes

Dr. Neelesh K. Jain

[3] LAPPING:
An Abrasive Surface-Finishing Process to Produce Surface Finishes of Extreme Accuracy and Smoothness Lapping is Used Cylindrical Surfaces for Flat and

The Abrasive Particles can either be Embedded in the Lap (Lapping Tool)
or

Carried as Fluid Suspension through between the Workpiece and Lapping Tool Abrasive + Carrier Fluid Lapping Compound [Has Appearance of a Chalky Paste] Carried Fluid: Oils, Greases, Water, Kerosene; Abrasives: Alumina or Silicon Carbide Lapping Tool is Made of a Material Softer than the Material to be Finished Cloth For Lapping Hardened Metals for Metallographic Examination Copper For Lapping of Diamond Fine-Grain Cast Iron Most Common Lap Material Leather, Wood, Steel Shape of the Lapping Tool is Reverse of the Desired Shape of Workpiece WORKING: The Lap is Pressed Against the Workpiece and Moved Back and Forth in a Figure of Eight or in Other Motion Pattern Over the Workpiece Surface Thus Abrasive Does the Cutting and Soft Lap is Not Worn Away because Abrasives Get Embedded in its Surface Instead of Moving Across it Sometimes Lapping can be Performed by Hand also. But for Greater Accuracy and Consistency Machines are Preferred
Finishing and Super Finishing Processes
Dr. Neelesh K. Jain

Lapping of Soft Materials is Difficult as Abrasives may get Embedded Centerless Lapping Machine is Used for Lapping Small Cylindrical Parts such as Piston Pins, BallBearing Races Lapping is Very Slow Method of Material Removal and is Costly as Compared to Other Finishing Methods MECHANISM: Two Alternative Cutting Mechanisms have been Suggested [1] Abrasive Particles Roll and Slide Between the Lap and Workpiece Cutting the Both Surfaces For Hard Laps [2] Abrasives Become Embedded in the Lap Surface and Cutting Action is Similar Grinding For Soft Laps PROCESS PARAMETERS Lapping Pressure: 7 kPa to 140 kPa (Depends on Workpiece Hardness) Abrasive Grit Size: 300 900 Achievable Surface Roughness: 0.025 0.1 m Dimensional Tolerance: 0.4 m APPLICATIONS: Finishing Metallic Bearing Surfaces, Gages Production of Optical Lens and Spherical Objects For Finishing Metallic and Non-Metallic Parts Subjected to Fatigue Loading For Finishing Liquid-Tight Surface that are Used to Establish a Seal with a Mating Parts For Doing Running-in of Mating Gears To Remove Scratch Marks Left by Grinding, Honing
Finishing and Super Finishing Processes
Dr. Neelesh K. Jain

[4] POLISHING
Used to Remove Scratches and Burrs and to Smoothen Rough Surfaces by Means of Abrasive Grains Attached to a Flexible Polishing Wheel or Belts Wheels or Belts are Made of Fabric, Leather, or Felt that are Coated with Fine Powders of Alumina or Diamond Abrasives are Glued to the Outside Periphery of the Wheel In Double-Sides Polishing, Pads are Fixed on the Faces of Platens that Rotate Horizontally in the Opposite Directions Two Basic Mechanism are Involved Fine-Scale Abrasive Removal Softening and Smearing of Surface Layers by Frictional Heating During Polishing Shiny Appearance of the Polished Surface Results from the Smearing Action Rotating Speed of the Wheel: ~ 2250 m/min Abrasive Grit Size: 20 to 80 For Rough Polishing 90 to 120 For Fine Polishing Polishing Operations are Often Accomplished Manually Parts with Irregular Shapes, Sharp Corners, Deep Recesses, and Sharp Projections are Difficult to Polish Other Polishing Operations [4.1] CHEMICAL MECHANICAL POLISHING (CMP): A Chemically Reactive Surface is Polished with a Ceramic Slurry in a NaOH Solution i.e. Polishing of Silicon Wafers [4.2] ELECTROCHEMICAL POLISHING (ECP): Reverse of Electro-Plating, can give Mirror-Like Finish Particularly Suitable for Irregular Shapes Can Also be Used for Deburring Operations
Finishing and Super Finishing Processes
Dr. Neelesh K. Jain

[4.3] MAGNETIC FLOAT POLISHING: Uses a Magnetic Fluid Containing Abrasive Grains, Extremely Fine Ferromagnetic Particles in a Carrier Fluid (Water or Kerosene) Filled in a Chamber within a Guide Ring Used for Polishing of Ceramic Balls Ceramic Balls are Located between a Drive Shaft and a Float (Made of Non-Magnetic Material) Abrasive Grains, Ceramic Balls, and Float are All Suspended by Magnetic Forces Balls are Pressed Against the Rotating Drive Shaft and are Polished by the Abrasive Action [4.4] MAGNETIC FIELD ASSISTED POLISHING: Used for Polishing of Bearing Rollers Ceramic or Steel Roller is Clamped and Rotated on Spindle Magnetic Poles are Oscillated, Introducing a Vibratory Motion to the Magnetic-Abrasive Conglomerate This Action Polishes the Cylindrical Roller Surface Bearing of Steel of 63 HRC have been Mirror-Finished with this Process

Finishing and Super Finishing Processes

Dr. Neelesh K. Jain

[5] BUFFING
Similar to Polishing in Appearance But its Function is Different Buffing is Usually Done Manually Like Polishing Differences Between Polishing and Buffing ? Buffing Wheels are Generally Softer Very Fine Abrasives are Used on Soft Disks Made of Cloth or Hide Abrasive is Supplied Externally from a Stick of Abrasive Compound Polished Parts may be Subsequently Buffed to Obtain an Even Finer Surface Finish Buffing is Used to Provide Attractive Surfaces with Higher Luster

Finishing and Super Finishing Processes

Dr. Neelesh K. Jain

[6] PEENING
A Cold Working Process Used to Improve or Alter the Surfaces of Metal Products Surfaces are Hit Repeatedly with a Large Number of Cast Steel, Glass, Ceramic Shots or Pellets or Small Balls or Round-Nose Tool Shots are Discharged from either from a Rotating Wheel or by an Air Blast from a Nozzle Highly Localized Impacts Flatten and Broaden the Metal Surface, but Broadening is Resisted by the underlying Material thus Inducing Residual Compressive Stresses on the Surface Induction of Compressive Residual Stresses on the Surface Improves the Fatigue Life of the Component Parameters: Shot Diameter: 0.125 5.0 mm Speed: 60 m/s Affected Depth: up to 1.25 mm Shot Peening can Cause APPLICATIONS: Shot Peening is Used for Primarily to Improve Fatigue Strength of the Parts Like Shafts, Gears, Springs, Crankshaft, Connecting Rod, Jet-Engine Parts (i.e. Turbine and Compressor Blades), Oil-Well Drilling Equipments [Surface Cleaning is Accomplished as by-Product of the Operation] To Produce Curvature on Thin Sheets i.e. To Produce Smooth and Complex Curvature on Aircraft Wing Skins To Straighten the Twisted or Bent Parts i.e. to Straighten the Out-of-Round Rings To Reduce the Residual Tension (caused due to Solidification Shrinkage and Thermal Contraction) in the Weldments thus Reducing Associated Distortion and Preventing Cracking
Finishing and Super Finishing Processes
Dr. Neelesh K. Jain

[7] BURNISHING: A Cold Working Process

Basically a Surface Plastic Deformation Process which Involves Rubbing a Smooth, Hard Object under Considerable Pressure over the Minute Surface Irregularities that are Produced during Machining or Shearing ROLLER or SURFACE BURNISHING: Hardened and Highly Polished Rollers Press Against the Surface and Deform Protrusions to a More-Nearly Flat Geometry Used on Various Flat, Cylindrical, and Conical Surfaces Used to Improve the Surface Finish by Scratches, Tool Marks and Pits and to Improve the Mechanical Properties of the Surfaces Used for Hydraulic System Components such as Seals, Valves, Spindles, and Fillets on the Shafts Can be Used for All Types of Metals, Soft or Hard BALL BURNISHING or BALLIZING: Used for Internal Cylindrical Surfaces A Smooth Ball Slightly Larger than the Bore Diameter is Pushed through the Length of the Hole Edges of the Sheet Metal Stampings can be Burnished by Pushing the Stamped Part through a Slightly Tapered Die having its Entrance Larger than the Workpiece and its Exit Slightly Smaller
Finishing and Super Finishing Processes
Dr. Neelesh K. Jain