i

INTRODUCTION
Praise be to Allah Subhanahu wa Ta'ala, because with His grace and mercy, the writer
and the team were given the opportunity to complete the Labwork Module for the
implementation of the manufacturing process practicum in the 2022/2023 educational year.

In this module the author and team redesigned our practical product masterpiece
Espresso Machine which consists of 39 main and supporting parts. This product is made for
the needs of integrated practicum activities in the Faculty of Industry and System
Engineering.

September 2022,

Manufacturing Process Laboratory Team

Manufacturing Process Laboratory Team

ii
 MANUFACTURING PROCESS LABORATORY ASSISTANTS 2022/2023

Adrian Wahyu Widiana Achmad Putra Sapujagad

Ahadiaz Daffa Nugraha Adelia Syanti Alam
Alyani Husniyah Aulia Nisaul Mufidah
Anizah Widya Sulistyaningrum Azyufito Azra Nasution
Ghanif Faoziansyah Dito Osama
Lukman Nul Hakim Erin Haynes
Mohammad Febrian Nugraha Fadhillah Apriliyani
Palma Artha Rahmadani Fadhly Ahmad Fachrezi
Pande Gd Agus Diva Prananda S. C Faisal Fathurrahman
Rizalulhaq Rasyid Novanto Fitra Hari Rhomansyah
Fransiskus Kevin Kristanto
Khulya Luthfianada
Muhammad Fikri Khaidar
Muhammad Latif Nur Hidayat Natasurya
Mochammad Yasser Yusuf
Naufal Hilman Syafiq
Ni Luh Gede Citra Puspitasari
Ni Made Dinda Gita Pramesthy
Rafifah Dwiariani
Rifa Amalia
Yonathan Janmorga
Zalfa Fadhilah Bacheramsyah

iii
 MANUFACTURING Document
PROCESS LABORATORY Number

MODULE 6 Form Number

Valid 2022

Module Assembly and Finishing

Labwork Assembly and Finishing

Student Outcome SO2. Able to apply mathematics, science and

engineering principles to solve complex
engineering problems in integrated systems
(including human, material, equipment, energy,
and information)

Learning Outcome LO13. Students are understanding the types of

material formation processes, machining and
finishing along with the characteristics and usage
in the manufacturing industry.

iv
A. Tools and Requirements
Tools & Software Requirements
1. Personal Computer 1. Labwork of Module 6
2. Parts of Espresso Machine 2. Assembly Process Chart of
3. Assembly Tools Espresso Machine
3. Safety Equipment
B. Reference

3DEXPERIENCE. (n.d.). Introduction to finishing processes. Retrieved from

https://make.3dexperience.3ds.com/processes/introduction-to-finishing-processes
Amir Dehghanghadikolaei, B. F. (2018). Abrasive Machining Techniques for Biomedical
Device Applications. Journal Material Science, 1-11.

Arief, I. (n.d.). KEY PARAMETERS IN LAPPING. 183-187.

Black, S. (2020). Structural adhesives, Part I: Industrial. Retrieved from Composites World:
https://www.compositesworld.com/articles/structural-adhesives-part-i-industrial

Brooker, K. S. (2013). Manufacturing Process Selection Handbook.

Ching-Lien Hung, L.-D. Y.-L. (2010). Magnetic Abrasive Finishing (MAF). Prediction system of
magnetic abrasive finishing (MAF) on the internal surface of cylindrical tube.

Colo. (2019). Electrostatic Powder Coating VS Fluidized Bed Powder Coating. Retrieved from
https://www.colopowdercoating.com/Electrostatic-Powder-Coating-VS-Fluidized-
Bed-Powder-Coating-id3222464.html

Derra, G. (2016). Curing Oven. High Power VCSEL Systems For Thermal Processing, 2.

Design, S. (n.d.). What is Anodizing Process: Alumunium Anodizing. Retrieved from

https://www.smlease.com/entries/finish-operations/what-is-anodizing/

Elliot, J. (2017). Advanced Spray Pattern and Pressure Distribution Testing. Retrieved from
PCI : https://www.pcimag.com/articles/103153-advanced-spray-pattern-and-
pressure-distribution-testing

Grill, J. (2022, March 8). Types of Welding Metal. Retrieved from

https://weldguru.com/welding-metals/

Groover, M. P. (2020). Fundamentals of Modern Manufacturing Materials, Processes, and

Systems Seventh Edition. WILEY.

Halevi, G. (2003). Process and Operation Planning. America: Kluwer Academic Publisher.

Hoffy, E. (2005). Advance Machining Process.

JAYSWAL, S. C. (2005). Magnetic Abrasive Finishing Process - A Parametric Analysis. Journal

of Advanced Manufacturing Systems, 131-150.

Kececi, E. F. (2019). Mechatronic Components. In Mechatronic Components.

Kwon. (2004). Grinding and Other Abrasive Process. Retrieved from

https://www.egr.msu.edu/~pkwon/me477/grinding

Ltd, G. M. (2015). History of Lapping Machine. Retrieved from News and Technology:
https://www.gmt.co.in/archive/news-history-lapping.htm

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LTD, N. W. (2016, September 2). Types of Welding Processes. Retrieved from
http://northern-weldarc.com/types-welding-processes/#comments

Malkin, S. (2013). Grinding Processes. Retrieved from

https://link.springer.com/referenceworkentry/10.1007%2F978-0-387-92897-5_602

Manufacturer, T. (2021, Mei 13). Different types of welding and what they are used for.
Retrieved from https://www.themanufacturer.com/articles/different-types-of-
welding-and-what-they-are-used-for/

Mehrdad Vahdati, S. R. (2016). Evaluation of Parameters Affecting Magnetic Abrasive

Finishing on Concave Freeform Surface of Al Alloy via RSM Method. Advances in
Materials Science and Engineering, 1-15.

Modul Praktikum Proses Manufactur . (2021). Bandung.

Modul Praktikum Proses Manufaktur. (2018). Bandung.

Muhammad Abdallha, S. A.-Z. (2020). Effect of Magnetic Abrasive Finishing Process on the
Surface roughness of CuZn28 With New Pole Geometry. Journal of Mechanical
Engineering, 256-264.

Project, S. H. (2017, Desember 1). Soldering Workshop. Retrieved from

https://sph.ethz.ch/event/soldering-workshop-2/

Tiwary, A. (n.d.). 11 Types of rivets & Their Basic uses with Diagram. Retrieved from
https://www.engineersrail.com/types-of-rivets/

twi-global.com. (n.d.). WHAT IS SOLDERING? A FULL GUIDE (MEANING, DEFINITION AND

TYPES). Retrieved from TWI: https://www.twi-global.com/technical-
knowledge/faqs/what-is-soldering

University, P. S. (n.d.). Metak Manufacturing: Joining and Assembly Processes. Retrieved

from
https://sites.esm.psu.edu/courses/emch213d/links/manufacturing/metals/joining_a
nd_assembly_processes.php

Velforce. (2020). VELFORCE Industrial Automation. Retrieved from https://velforce.com/

Vishwanath Patil, J. A. (2021). MAGNETIC ABRASIVE FINISHING. Novateur Publication’s, 1-5.

Wengh, F. (n.d). Arbeitsmaterial f Lernenden "Nieten". Retrieved from

http://www.nzdl.org/cgi-bin/library

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C. Labwork Steps

Flow Process Chart Process Description

1. Read the study case well, because
the study case contained
information that will be carried out.
2. Pay attention to the video, because
the video contains how to an
assembly espresso machine.
3. Do the assembly and disassembly of
the espresso machine based on the
Assembly Process Chart.

vii
 MODULE 6
ASSEMBLY AND FINISHING

1. OBJECTIVES
1.1 Students are able to understand about assembly process in manufacturing
1.2 Students are able to understand about the tools used for assembly and finishing
process in manufacturing
1.3 Students are able to implement concept and principal of assembly and finishing
process into practice

2. OUTLINES
2.1 Introduction of Assembly Process
2.2 Tools, Fixtures, and Equipments
2.3 Types of Assembly Process
2.4 Factors Affecting Assembly
2.5 Types of Joint
2.6 Mechanical Fastening Methods
2.7 Introduction of Finishing Process

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3. BASIC THEORY
3.1 Introduction of Assembly Process
Assembly is a process of drafting, combining, and setting several parts into a
part that has a function. Assembly started when an object is ready to be installed and
ended when the object is assembled perfectly. This process can be done temporarily
with fasteners or permanently by welding or gluing. The work of the assembly process
is carried out by setting up machines, equipment, and workers where the products to
be assembled are passed sequentially from one operation to another until they are
completed (Kececi, 2019).
Choosing the right method for the part that we want to assemble is important
before the assembly process is carried out. The assembly method can be selected by
the engineers after the product design is completed, approved, and authorized.
Operators are expected to understand how to plan assembly methods for effective
manual assembly, semi-automated assembly, and automated assembly.

Figure 6. 1 Assembly Process

3.2 Tools, Fixtures, and Equipments
To produce the most efficient assembly procedure, assembly level is required
which is a key factor in the type and level of assembly equipment, fastener fixing tools,
and joining equipment. Therefore, making an initial decision on the number of tools,
fixtures, and equipment also have a long-term effect on the economic factors and the
integrity of the product. The following tools and equipment are commonly used:
1. Wrenches
2. Electric, pneumatic, and hydraulic drivers
3. Jig, fixtures, and clamps for positioning components and ease assembly due

2
 to ergonomics factors
4. Utility supply lines
5. Part feeders, vibratory hopper bowls and tracks, inspection gauges, and
machinery for delivering components and fasteners to the assembly site
6. Automatic installation equipment and robots
7. Numeric and computer controllers for programming fastening installation
procedure.
Equipment selection can be made for assembly work by estimating the number
and speed at which the assemblies will be worked and joined. In this way, the
manufactured product will be strong, durable, and efficiency can be achieved for the
assembly manufacturers.
3.3 Types of Assembly Process
There are three types of assembly processes and mostly used in industry, which
are manual assembly, semi-automated assembly, and automated assembly.
1. Manual Assembly
Manual assembly operations are performed by human workers
using their inherent dexterity, skill, and judgment. A manual assembly line
consists of multiple workstations arranged sequentially. The usual
procedure on the manual path starts with the base part. Then, the base
part walks through each station where workers do the assembly of the
other parts. After all the parts have been completed, the product will leave
the final station (Groover, 2020).

Figure 6. 2 Manual Assembly (Groover, 2020)

3
2. Semi-Automated Assembly
Semi-automated assembly is a process carried out by the combined
activities of humans and machines that aim into one finished product. Many
manufacturers choose to implement semi-automated because of the
complexity of the task, or the number of products produced is too low if
carried out with a fully automated process (Langer & Soffker, 2011).

Figure 6. 3 Semi-Automated Assembly (Velforce, 2020)

3. Automated Assembly
Automated assembly is an integrated system and operates under
the control of a computer. Automated assembly systems consist of one or
more workstations that perform assembly operations, such as adding
components to a work unit. Operations performed by stations tend to be
simpler than those performed by humans. So that, the task becomes easier
to automate. Automated assembly is usually widely used for the mass
production of small products such as pens, cigarette lighters, and flashlights
(Groover, 2020).

Figure 6. 4 Automated Assembly (Groover, 2020)

4
3.4 Factors Affecting Assembly
There are several assembly methods based on mechanical interference
between the two parts being joined. There are several success factors in assembling a
product, including:
1. Types of Material
Every material has its own characteristics, these characteristics will
determine which assembly method is the most suitable to be used in the
assembly process. There are some types of materials such as metal,
ceramic, polymer, composite, semiconductor, etc.
2. Material Strength
Consideration of the power required for a product should have been
designed when planning what will be explained by considering what the
product used. On this basis can choose the connection method in the basic
assembly process for the product of the power connection required.

3. Selection of Joining Method

The selection of joining method is closely related to the type of
materials and the power connection because each method of connection
has its own usability.
4. Strengthening Method Selection
The strengthening of plates aims to give rigidity to the plate subjected
to the process of information. Because the base material of this plate is
relatively thin, it usually needs to strengthen the plate either on the edges
or on the body.
5. Tolerance
Tolerances in elements based on the recommendation of intermediate
pairs are assembled into a larger component.
6. Form/Display
The appearance of a product affects the selling value of the product
itself. The appearance usually begins with the image or design. A display
adapted to use of the product in the process.

5
 7. Ergonomic
Ergonomic defined in this assembly is a match between the products
with the convenience of the user (end-user). This means that the product
used does not cause fatigue, danger, boring, etc.
8. Finishing
Finishing or final work is important in the process of assembly. Finishing
will give the final appearance of an object to the sale value.
3.5 Types of Joint
Joint function is to fasten a machinery construction, either semi-permanent or
permanent. Joint is always used in composite structure assembly because of its cost
efficiency and accessibility.

1. Semi-Permanent Joint
This type of joint is a method of joining that is usually designed to
be permanent. However, it can be disassembled without damaging the
materials. For example, with the use of bolts, nuts, and washers as well as
knock-down fittings.
a. Bolt
Bolt is an externally threaded fastener that is inserted
through holes and “screwed” into a nut on the opposite side.
These are designed to tighten them. Some bolt heads
automatically lock the bolt in place. So that, it does not move
and a tool is only needed for the nut end (Groover, 2020).
Table 6. 1 Type of Bolt
No Type Picture Explanation

Elevator bolt is threaded

fasteners consisting of a
1 Elevator Bolt threaded shank to hold the
canvas. They have a flat
head

6
 Table 6. 2 Type of Bolt (cont.)
Timber bolts are also
referred to as dome head,
fender head, safety head,
and mushroom head bolts.
They are used in marine
2 Timber Bolt
and wood applications.
The underside of the head
timber bolt has nubs or fins
which prevent the bolt
from turning in the timber

Hex bolts are bolt

hexagonal head with
3 Hex Bolt threads to use with a nut
or tapped hole.

Lag bolts are generally

used to connect heavy
lumber and other
4 Lag Bolt materials that bear an
intense load. They have a
hex head.

Plow bolts are used for

attaching the cutting edge
of a plow to the plow
blade. Typically used for
bonding wood and locking.
5 Plow Bolt
blade components on
dozers and graders that
are in direct contact with
the ground requiring heavy
work.

Anchor bolts are usually

embedded in concrete or
6 Anchor Bolt
brick for structural
applications.

This type of bolt has a short

Machine shank and is used to join
7
Bolt metal components
through pre-drilled holes.

7
 Table 6. 3 Type of Bolt (cont.)

T-head bolt has a large T-

shaped head that can be
8 T-head Bolt
gripped by a winch and can
fit into a slot with ease.

b. Nut
A nut is an internally threaded fastener that must fit with
a bolt followed by the same thread diameter, pitch, and shape.
Table 6. 4 Type of Nut
No Type Picture Explanation
Hex nut has a six-sided nut
also referred to as a
finished hex nut. Hex nut
can use with anchors,
1 Hex
bolts, screws, studs,
threaded rods, and any
other fastener with
machine screw threads.
Heavy hex has a heavier
patterned version of a
2 Heavy Hex standard hex nut, heavy
hex nuts are the strongest
of all nut designs.

A nut with nylon inside to

Nylon Insert prevent the backing of also
3
Lock referred to as nylon. They
have metric sizes.

A hex nut with reduced

4 Jam
weight.

Insert Jam A nylon hex with reduced

5
Lock weight.

A non-reversible lock nut

Prevailing
6 uses for high-temperature
Torque Lock
applications.

A nut with a built-in

washer-like flange and
7 Flange
have metric size M10 to
M100.

8
 Table 6. 5 Type of Nut (cont.)

A nut is designed to be
8 Tee driven into the wood to
create a threaded hole.

A nut with wings for hand

9 Wing tightening. They have
metric sizes M10 to M100

A nut with a domed top

10 Cap over the end of the
fastener.

Acorn nut with a high

crown type of cap nut used
11 Acorn
for appearance and have
metric size M10 to M100

2. Permanent Joint
The permanent joint cannot be disassembled without destroying
the connecting components. There are some types of permanent joints:
a. Riveted Joint
Rivets are widely used to achieve mechanically bonded
permanent joint that has simplicity, strength, density
(tightness), and low cost (Groover, 2020). Rivets are bolt-like
devices made up of ductile metals, which are inserted through
parallel holes drilled across the joining members and punched
from the other side to produce perfect and permanent firm
locking joints. There are some applications using a riveted joint,
including:
a) Strengthening joints in light metal products such as
multilevel construction, bridge construction, and
aircraft construction.
b) Impermeable joint for water tank, chimney plates,
and pipes.
c) Joint nails for aircraft and vehicle construction.

9
 Table 6. 6 Type of Riveted Joint
No Type Picture Explanation

Button head rivet is a

variation of blind rivets
Button Head that feature cylinder-
1
Rivet shaped heads with
rounded tops and flush
bearing surfaces.

Countersunk rivet is used

to join work-piece
Countersunk materials together where
2
Rivet the head of the assembled
rivet will be flush with the
top of the workpiece.

This type of rivet is used for

such parts where the
Oval Head
surface is rough, and
3 Countersunk
uneven and no special
Rivet
demands are made on the
quality of the surface.

Pan head rivet is slightly

Pan Head
4 rounded with short vertical
Rivet
sides.

Conical head rivets are

Conical
5 used for light work and
Head Rivet
done by hammering.

Belt rivets is usually used

for connecting soft
6 Belt Rivet
materials such as leather,
rubber, or felt.

Hollow Rivet
This type of rivet is used to
7 or Tubular
connect delicate materials.
Rivet

b. Welding
Welding is a material joining process in which two or
more parts are assembled at their contacting surfaces by a
suitable application of heat and/or pressure. Several welding

10
processes are accomplished by heat alone, pressure, or by a
combination of heat and pressure. In some welding methods, a
filler material is added to make the merging of the materials
easier. Welding is most associated with metal parts, but the
process is also used for joining plastics. The welding processes
can be divided into many types, such as arc welding, resistance
welding, and oxyacetylene welding (Groover, 2020).
Table 6. 7 Type of Welding
No Type Explanation

Arc
1
Welding
Arc welding is one of the welding processes
in which heating of the metal is heated using
an electric arc. Some of them also apply
pressure during the process and most utilize
a filler metal.

Resistance
2
Welding
Resistance welding is a fusion-welding
process that uses a combination of heat and
pressure to accomplish coalescence, the
heat being generated by electrical
resistance to the current flow at the junction
to be welded.

Oxyacetyle
3
ne Welding
Oxyacetylene welding is a fusion-welding
process performed by a high-temperature
flame from the combustion of acetylene and
oxygen. Sometimes added filler metal and
pressure

11
There are some types of welding metals used, including:
a) Steel
Steel is an alloy that contains iron and 2% of
other elements, carbon/steel alloy is common and
can be found in high, low, and medium varieties. The
characteristics of steel are higher carbon content
means stronger steel, versatile, and can be used with
any welding process. On the other side, it can rust
and flake from oxidation.
b) Stainless Steel
Stainless steel is made to resist corrosion and
is hygienic. This is achieved by adding 10% to 30%
chromium to other elements such as iron. There is
also a nickel alloy available. Stainless is welded using
arc welding. The downside is the higher cost.
c) Aluminum
Like stainless steel, aluminum also isn’t as
corrosive as other metals. It is lighter than stainless
steel. In welding, pure aluminum and alloys are used.
Alloys include copper/aluminum alloy, manganese
alloy, and zinc alloy. Several types of arc welding
which are Gas Metal Arc Welding (GMAW) and Gas
Tungsten Arc Welding (GTAW) is the process of
choice for welding aluminum. Stick aluminum
welding is only used for smaller projects.
d) Copper
Among the welding metals, copper is popular
due to its electrical conductivity, heat conductivity,
corrosion resistance, appearance, and wear
resistance. To be called copper, it needs to be a
99.3% minimum copper content. Copper is welded
using GMAW and GTAW. The shielding gas for
copper is welding-grade argon. Oxides that form

12
 should be removed after welding. Copper is
preheated. However, copper alloys do not need to be
preheated due to high levels of thermal conductivity.
e) Cast Iron
In terms of welding metals, low-carbon steel is
easier to weld than cast iron. Cast iron has higher
carbon and silicon content and is not as ductile.
When welding with cast iron, the surface will need to
be cleaned to remove any ingrained grease and oil.
All cracks need to be ground or filed. Cast iron is
welded with oxyacetylene welding.
f) Magnesium
Magnesium alloys are lightweight (2/3 of
aluminum), absorb vibration, and easy to cast. It has
a melting temperature similar to aluminum and is
welded in a similar way. When you grind magnesium,
the shavings are flammable. The metal is welded
with a GTAW.
c. Brazing
Brazing is a joining process in which a filler metal is
melted and distributed by capillary action between the faying
surfaces of the metal parts being joined (Groover, 2020). The
filler metal must have a melting point that is above 840 degrees
Fahrenheit but below the melting point of the base metals and
the metal must also have high fluidity and wettability.

Referred to as brazing processes, they are differentiated

by their heating sources. There are three types of brazing, such
as torch brazing, induction brazing, and resistance brazing.

13
 Table 6. 5 Type of Brazing
No Type Explanation

Torch
1
Brazing

Flux is applied to the part surfaces and a

torch is used to direct a flame against
the work in the vicinity of the joint.

Induction
2
Brazing

Utilizes heat from electrical resistance

to a high-frequency current induced in
the work.

Resistance
3
Brazing

Heat to melt the filler metal in

resistance brazing is obtained by
resistance to the flow of electrical
current through the parts.

14
 d. Soldering
Soldering is similar to brazing. On soldering, no melting
of the base metals occurs, but the filler metal wets and
combines with the base metals to form a metallurgical bond.
The difference between soldering and brazing lies in the heat
and temperature required for soldering are lower than brazing.

Figure 6. 5 Soldering (twi-global.com, n.d.)

e. Adhesive Bonding
Adhesive bonding is a bonding process in which a filler,
called an adhesive material, is used to hold two (or more) closely
spaced parts together to the bonding surface. Adhesives are
non-metallic substances, often it is a polymer.

Figure 6. 6 Adhesive Bonding (Black, 2020)

3.6 Mechanical Fastening Methods

Several additional methods involve the use of fasteners. Stitching and stapling
industries are similar operations involving the use of U-shaped metal fasteners.
1. Stitching
Stitching is a fastening operation in which a stitching machine is
used to form the U-shaped stitches one at a time from steel wire and
immediately drive them through the two parts to be joined. Applications of
industrial stitching include light sheet metal assembly, metal hinges,

15
 electrical connections, magazine binding, corrugated boxes, and final
product packaging (Groover, 2020).
2. Stapling
The staples are supplied in convenient strips. The individual staples
are lightly stuck together to form the strip, but they can be separated by
the stapling tool for driving. Staples are usually applied using portable
pneumatic guns, into which strips containing several hundred staples can
be loaded. Applications of industrial stapling are usually used on furniture
and upholstery, the assembly of car seats, and various light-gauge sheet
metal and plastic assembly jobs (Groover, 2020).
3. Sewing
Sewing is a common joining method for soft, flexible parts such as
cloth and leather. The method involves the use of a long thread or cord
interwoven with the parts so as to produce a continuous seam between
them. The process is widely used in the needle trade industry to assemble
garments (Groover, 2020).
3.7 Introduction of Finishing Process
The finishing process has the purpose of changing the surface of the parts
produced to achieve certain characteristics. The desired characteristics desired in the
finishing process include an increase in aesthetics, adhesion, solderability, chemistry,
corrosion, tarnish, or wear-resistant, hardness, electrical conductivity, disability
removal, and surface friction control. In the finishing process, these processes take
off/ reshape the finishing or add/ change the finishing.
1. Abrasive Machining
Abrasive machining is a technique of material removal that is
introduced in order to cut workpiece materials by an abrasive medium
that can be in the form of water, abrasive particles, or a mixture (Amir
Dehghanghadikolaei, 2018). An abrasive is a small hard particle having
sharp edges and an irregular shape. Abrasives can remove tiny amounts
of material from a surface through a cutting process that produces tiny
chips. Other abrasive processes are honing, lapping, superfinishing, and
grinding.

16
a. Honing
Honing is an abrasive process performed by a set of
bonded abrasive sticks using a combination of rotational and
oscillatory motion. A common application is to finish the bores
of internal combustion engines. Other applications include
bearings, hydraulic cylinders, and gun barrels. Usually used to
fill holes in internal combustion engines. Surface finish 0.12 m
(5 -in) or better (Groover, 2020).
Honing tools are plastic gears impregnated with fine
abrasive particles. The honing process is faster than grinding
and is used to improve the surface finish. To further enhance
the surface finish, the grinding teeth are spliced, using an
abrasive compound with a cast iron or bronze gear-shaped
beater or a pair of mating gears actuated together.

Figure 6. 7 Honing (Groover, 2020)

b. Lapping
Lapping is an abrasive process used to produce a
surface finish with very high accuracy and smoothness. The
lapping process is gentler than superfinishing and sharpening
and removes less surface material. The lapping tool is called a
lap. 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

17
 accomplish the process with greater consistency and
efficiency (Groover, 2020).
With a certain force and speed, abrasive particles
which are harder and crystalline tourer than workpiece
materials, remove small chips from the workpiece. The
application of the lapping process, such as optical lenses,
metallic bearing surfaces, and gages.

Figure 6. 8 Lapping (Ltd, 2015)

c. Superfinishing
Superfinishing is used to refine the surface finish of a
component with an exceptionally low roughness average.
Superfinishing can be used to finish flat and external
cylindrical surfaces. Superfinishing is an abrasive process
similar to honing. Both processes use bonded abrasive sticks,
pressed against the surface, and reciprocating motion. But the
difference in superfinishing, has shorter strokes, higher
frequencies, lower pressures between tool and surface, lower
work speed, and smaller grit sizes. The result from
superfinishing is mirror-like finishes with surface roughness
values around 0.025 μm (1 μ-in) (Groover, 2020).

Figure 6. 9 Superfinishing (Groover, 2020)

18
d. Grinding
Grinding is a material-removal process accomplished
by abrasive particles wheel rotating at very high surface
speeds. The grinding wheel is usually disk-shaped (Groover,
2020). The grinding process of shaping materials is probably
the oldest. dating from the time prehistoric humans, found
that they could sharpen their tools by rubbing them against
gritty rocks. There are numerous types of grinding operations,
which vary according to the shape of the wheel and the
kinematic motions of the workpiece and wheel head.

Table 6. 6 Type of Grinding Machines

No Types Picture Explanation

Cylindrical grinding is
used for rotational
Cylindrical
1 parts and shaping the
Grinding
inside or outside of a
workpiece.

Centerless grinding is
a type of grinding
machine which uses
Centerless two rotary wheels to
2
Grinding secure the workpiece
in place and the
workpiece is not held
between centers.

A Tool and Cutter

Tool and Grinder is used to
3 Cutter sharpen milling
Grinding cutters, tool bits, and
other cutting tools.

Surface grinding is
normally used to grind
plain flat surfaces. It is
Surface performed using
4
Grinding either the periphery of
the grinding wheel or
the flat face of the
wheel.

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2. Magnetic Abrasive Finishing (MAF)
Magnetic abrasive finishing is one of the non-traditional finishing
processes, which produces a high level of surface quality and is primarily
controlled by a magnetic field. In this process, the workpiece is kept
between the two poles which are the north and south pole. The working
gap between the workpiece and the magnet is filled with magnetic
abrasive particles (Muhammad Abdallha, 2020).
A special benefit of this finishing process is the possibility of
finishing complex surfaces. Magnetic abrasive finishing is used for
complicated product finishing, roughness, and tolerance that are difficult
to achieve using conventional machine processes (Vishwanath Patil,
2021).

Figure 6. 10 Magnetic Abrasive Finishing (Mehrdad Vahdati, 2016)

3. Spraying
Spraying is a painting technique that employs a spraying device,
usually coupled with compressed air, to air-spray a workpiece with a
choice of coating (3DEXPERIENCE, n.d.). The main benefits of spraying
include:
a. Saving time
When working on a project, using a brush to paint takes
a lot of time when compared to a paint sprayer.
b. Ease to use
Spray paint saves you from a lot of unnecessary effort.
You do not need to refill your brush with liquid paint
constantly.

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 c. Giving more control
The adjustability options in a spray painter are
unparalleled. Even with the base tool, you have flexibility over
the amount of paint you want to discharge.
Airbrushes and spray guns are distinguishable by their sizes and
by the size of spray the pattern they produce. While airbrushes are hand-
held, they are typically applied to projects that require a greater amount
of detail such as fine art, small nails, or photo retouching. The equipment
used with spray guns is generally quite large. Spray guns are typically well
suited for covering large surfaces with an even liquid coat. Their
interchangeable heads allow users to spray different patterns and they
can be either automated or handheld (3DEXPERIENCE, n.d.).

Figure 6. 11 Spraying Process (Elliot, 2017)

4. Powder Coating
Powder coatings are applied as dry, finely pulverized, solid
particles and melted on the surface to form a uniform liquid film, after
that they resolidify into a dry coating (Groover, 2020). Powder coating is
one of the most popular forms of surface finishing with the results are
highly durable, yet still as smooth, shiny as paint, high quality and is
widely used for both protection and decoration.
Electrostatic spray guns also called liquid electrostatic sprays are
one of several powder coating application processes due to the concepts
of charge and electric fields. The final process is the curing process which
involves exposing the workpiece to elevated temperatures for a set
duration so that the powder melts, flows out, and chemically reacts to
harden and dry. Some of the most common metals under a powder

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 coating process include household appliances, automotive, and bicycle
parts. The main benefits of powder coating include:
a. Efficiency
b. Low cost
c. Durability
d. Creating a smooth surface without drips or runs,
e. Ease of maintenance.

Figure 6. 12 Powder Coating Process (Colo, 2019)

5. Anodizing
Anodizing is commonly applied to aluminum alloy and substrates
that are performed to increase the thickness of the natural oxide layers
on the surface of metal parts. The anodizing process employs electrolytic
passivation to achieve the desired properties such as corrosion and wear
resistance, better adhesion for paint and glue, or for aesthetic effects.
Anodizing produces a stable oxide layer on a metallic surface. For
aesthetic effects, thick, and porous coatings enable a dye to be absorbed
while thin transparent coatings can add interference effects to reflected
light. The main benefits of anodizing include:
a. Significantly thinner coat than paint or powder
b. Extremely durable, hard, abrasion-resistant, and long-lasting
c. No peeling or chipping, much harder surface than paint, and
color fade resistance
d. Excellent corrosion protection
e. Environmentally friendly

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f. Affordable

Figure 6. 13 Anodizing (Design, n.d.)

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