ABOUT US

SPEEDFAM INDIA PVT LTD is one of the leading FLAT

SURFACE LAPPING & POLISHING MACHINE
manufacturer in India, manufacturing these machines
in techno-commercial collaboration with SPEEDFAM
CO. LTD. JAPAN since 1991.

We have over 400+ installations all over India &

neighbouring countries for variety of flat surface
applications like mechanical seals, valve plates, fuel
injection components, auto parts, watch glass & dials
etc.

ISO 9001: 2000 certified company for last three years.

 INTRODUCTION

What is lapping?
Lapping is a fine finishing process carried out by the abrasive
particles in order to produce superior surface finish. Normally, it
is being used after grinding in order to improve surface
parameters. It is used as a method for obtaining very close fits
between mating parts. The parts to be lapped may either be flat
or cylindrical.

What is polishing?
Polishing is a process employed in order to improve surface
finish after lapping, to achieve mirror finish on the components.
It is used for the mating parts which calls for leak less joints or
the parts which needs high degree of mirror finishing for
aesthetic purposes.
BASICS OF LAPPING/POLISHING
Lapping is done either manually called as HAND LAPPING or
on the machine called as MACHINE LAPPING
The loose abrasive in the form of paste or mixed with oil or
fluid is being applied on the plate & the component being
processed is rubbed against the abrasive particles.
The cutting action is being generated from the grain of the
abrasives while pressure (either self weight or added) is being
applied on the component while it is rotated over the abrasive
particles.
The component is being rotated in such a way so as to form 8
shape rotation for effective lapping.
Lapping is done in stages from coarser to finer preferably with
separate sets for lapping/ polishing steps.
 WHY LAPPING/POLISHING
Lapping / polishing is done to achieve

Flatness
Surface finish
Parallelism
Thickness tolerances
 HOW TO ACHIEVE FLATNESS
Figure 1

Lap plate having desired flatness

Flatness:
Figure 2
It entirely depends on the lap
Lap plate is charged with abrasive plate flatness. It is the replica
particles of plate flatness produced on
Figure 3 the parts to be lapped. Hence
selection of proper plate
Component needs to be lapped for flatness of the lap plate is
FLATNESS
utmost important & is basic
Figure 4 need of the operation.
Component is rotated over the plate It is measured in terms of light
with pressure band with monochromatic light
& optical flat.
Figure 5

Component starts generating

FLATNESS

Figure 6

Component has achieved FLATNESS

 HOW TO ACHIEVE SURFACE
FINISH
Figure1

A component is rubbed over abrasive

particle
SURFACE FINISH:
Figure 2 The selection of abrasive grit
& type will produce desired
Due to rubbing action between
abrasive particle & component, surface finish. Abrasive is one
surface is being cut producing ups / of the most important selection
dips on the face. This is called as
surface roughness / surface finish of
criteria to decide the same.
the part. It is measured in terms of Ra /
Rz / Rmax.
Figure 3

Bigger the particle size, rougher the

surface finish, producing big ups &
dips (peaks / valleys)

Smaller the particle size, smoother the

surface finish
 HOW TO ACHIEVE
PARALLELISM / THICKNESS
TOLERANCES
THICKNESS TOLERANCES:
It is the ability of machine to produce the components in desired
thickness tolerances. The processing type plays major role in the
same.
PARALLELISM:
It is being governed by the processing method on the machine to
achieve desired parallelism tolerances.
 SELECTION FOR MECHANICAL
SEALS
Seals are being classified primarily as Hard faces & soft faces.
Hard faces are CERAMIC, TC, SiC, WELDED OR COATED
FACES.
Soft faces are CARBON, BRONZE, GFT etc.
Hard faces are generally finished in three stages ROUGH LAPPING,
FINISH LAPPING, POLISHING.
Soft faces are normally done in two stages LAPPING, POLISHING.
 PROCESS FOR FACE
LAPPING/POLISHING
Rough Finish Lapping Polishing
Lapping
Ceramic,TC, Square groove Radial groove Copper Spiral +
SiC, C.I Plate+ C.I.Plate+ Diamond
Diamond Diamond
Carbon Radial groove Copper / Tin plate
C.I Plate+ + Diamond(dry
Al2O3 abrasive process)
Bronze Radial groove Pad Plate +
C.I Plate+ Diamond
Al2O3 abrasive
SS Radial groove Pad Plate +
C.I Plate+ Diamond
Al2O3 abrasive
 PLATE CONFIGURATIONS
SQUARE GROOVE
- FAST STOCK REMOVAL
- MORE CUTTING EDGES
- CAN APPLY HIGHER PRESSURE
- EASE IN REMOVAL OF LEFTOVER

RADIAL GROOVE
- MODERATE/LOW STOCK REMOVAL
- BETTER FLATNESS CONTROL
- LIMITED CUTTING EDGES

PLAIN
- VERY LOW STOCK REMOVAL
- IMPROVED SURFACE FINISHING
- GOOD FLATNESS ON PARTS

SPIRAL
- EXTREMELY SUITABLE FOR POLISHING
- MAXIMUM COMPOUND UTILISATION
- ALLOW PRESSURE DURING OPERATION
PROCESS CONSUMABLE
ROUGH LAPPING OF HARD
FACES
- DIAMOND PASTE FROM 70 MICRON
- 25 MICRONS
- BORON CARBIDE FROM 80 MICRON
- 25 MICRONS
- SILICON CARBIDE FROM 80 MICRON
- 25 MICRONS

FINISH LAPPING OF HARD

FACES
- DIAMOND PASTE FROM 15 MICRON
- 6 MICRONS
- BORON CARBIDE FROM 15 MICRON
- 6 MICRONS
- SILICON CARBIDE FROM 15 MICRON
- 6 MICRONS

POLISHING OF HARD
FACES
- DIAMOND PASTE FROM 3 MICRON -
0.5 MICRONS
PROCESS CONSUMABLE
LAPPING OF SOFT FACES
- ALUMINIUM OXIDE POWDER /
PASTE FROM 25 MICRON - 8
MICRONS

POLISHING OF SOFT
FACES
- DIAMOND PASTE FROM 3 MICRON
- 0.5 MICRONS
(PREFERABLY DEPOSITED /
CHARGED PLATE FOR CARBON)

- POLISHING ALUMINA OF LESS

THAN 1 MICRON PARTICLE SIZE.
 HOW TO MEASURE FLATNESS

There are several ways to measure flatness

1. You could place a straight edge on the surface & look
for daylight between the straight edge & the component.
2. You can apply machinist blue die on the known flat
surface, rub the component against it & look for transfer
of the dye.
These two methods are not accurate enough for
determining mechanical seal face flatness.
The widely accepted method is by using optical flat &
monochromatic light source to determined flatness.
MONOCROMATIC LIGHT
PRINCIPLE OF
MONOCHROMATIC
LIGHT: A single wavelength light
source (helium or Sodium) is used
to check the component whose
flatness needs to be determined.
The component is placed below
the light. The optical flat which is
ground & polished with defined
accuracy is placed on the
component. The light reflects off of
the piece back through the optical
flat causing interference light
bands. The band pattern is seen
on the surface of the component to
be checked which determines
flatness of the component.
FLATNESS MEASUREMENT
LIGHT BAND MEASUREMENT
OF FLAT SURFACES
Straight, parallel lines or bands
indicate true flatness
The flatness is read from the number
of bands intersected by a tangent
line to any curve, counted from the
point of greatest curvature to one
side of piece. Above work piece is
1band out-of-flat.
Illustration shows low area or grove
in work piece of 1/2 band deep and
a drop-off area at lower right hand
edge of 1band.
Shown here is edge rounding or
"Dubbing" of 1/2 band.
If broadening of light bands occurs
when pressed at the center, the
piece is concave
Either concave or convex pieces
may show as a "Bulls-Eye" design. If
Bulls-Eye" moves toward point of
pressure when pressed on edge the
piece is convex.
 HOW TO MEASURE SURFACE
FINISH

Surface finish addresses the subject of roughness & is

measured in terms of rms or CLA.
There are several ways to measure the surface finish
such as comparison method, profilometer or by surf
tester.
TIPS FOR LAPPING/POLISHING
1. The abrasive should be as hard as the metal being
lapped.
2. A non-embedding or non-charging compound should be
used for soft metals, for instance, Garnet abrasive for brass
or bronze.
3. The softer the metal, the softer the abrasive . The harder
the metal, harder the abrasive.
4. Serrated or grooved plate configuration is best for flat
surfaces with large areas, also for flat areas with holes in
the surface.
5. Plates with no serration or grooves are preferred for
cylindrical lapping.
6. Abrasives when mixed into an oily paste or greasy
vehicle will give better results than just a mixture of fluid
oils and abrasives.
7. Tungsten carbide is best lapped with Diamond
compound.
TIPS FOR LAPPING/POLISHING
8. A gray or frost-like surface may be as smooth and
accurate as a bright finish.
9. A polished surface is harder to produce than a gray
matte finish and will show scratches more readily.
10. It is more difficult to lap soft metals than hard metals.
11. A soft lap will cut faster than a hard lap. It will wear
longer and give a brighter surface. A hard lap cuts slowly,
wears slowly and gives a dull finish, but its accuracy of
lapping is greater.
12. .Use lapping compounds sparingly. Too much is worse
than too little. Excess compound removes metal but does
not correct the error in parts.
13. Final finishing should be done only with a charged lap
lubricated with thin oil, naphtha, gasoline, spindle, etc.
14. Thin work pieces can be lapped parallel but not
necessarily flat.
15. Final finishes are best obtained with no loose abrasive
on the plate. Use the embedded abrasive granules in the
surface of the plate and a very thin lubricant.
16. When soft metal parts such as brass or bronze seals are
lapped, a non-embedding abrasive should be used.
 TIPS FOR LAPPING / POLISHING
17. Red Rouge (Ferric Oxide) is recommended as a
polishing medium for soft metals.
18. Green Rouge (Chromium Oxide) is well suited for the
polishing of stainless, chrome and other hard metals. Also
for plastic.
19. Different kinds of abrasives or grit sizes should not be
used at the same time on the same plate. It is recommended
to use one plate for roughing operation and another plate
for finishing operations.
20. Diamond compounds should be used for lapping
tungsten carbide or other hard metals where the hardness
exceeds 64 Rc.
21. An abrasive particle will produce a scratch one fifth of
its size. Thus a 10 micron sized particle will produce a
scratch of 2 microns.
22. Brightness does not indicate flatness. A gray or matte
finish can be just as smooth and accurate as a bright finish.
23. Fine abrasive grit sizes do not mean fine finishes. The
abrasive should be just coarse enough to abrade or remove
the desired amount of stock of metal which causes the
abrasive granules to break down into finer sized particles.
These fine particles produce the desired finish.
TIPS FOR LAPPING / POLISHING
24. Every abrasive has a different finishing quality as to
brightness or reflective ability. Silicon Carbide abrasive, no
matter how used, will only produce a gray, frosted or matte
finish.
25. The crushed abrasive granules creates a protective medium
between the lap and part.
26. For lapping various grades of aluminum metal the Gamet
and Silicon Carbide compounds are recommended. Linde
powders are used to create a high polish or mirror finish.
27. For lapping hardened steels, stainless, chrome plate, etc.
(Rockwell C 55-63), the white Aluminum Oxide abrasive
compounds are recommended. The white Aluminum Oxide
abrasive is recommended also for beryllium and ceramics.
28. The Corundum abrasive is well suited for softer steels. 29.
Carbon seals should not be lapped with loose abrasive on a
plate. The lapping plate should be a bonded abrasive disk
using a thin oil lubricant.
30. Surface finish is a function of abrasive grit size, part
material and part hardness. Coarse abrasives produce higher
surface finish than finer abrasives. Harder materials exhibit
lower surface finishes from a given abrasive than softer
materials.
 WHAT WE OFFER
Flat surface lapping / polishing machine
Flatness measuring instruments
Process consumables
In-plant training for technicians / Engineers
Demonstration / Trials for new components
Process back - up / Selection of consumable
Information on allied equipments for enhance performance
of lapping machine