 The parts produced by various machining

operations like turning, drilling, milling etc.

although are fairly accurate in size.
 They do not carry a very high degree of surface

finish.
 In many industrial applications ,very high

degree of surface finish is required.

 When very high dimensional accuracy is
required following operations are performed……

1)Special grinding operations.

2)lapping,
3)Honing,
4)superfinishing.

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 POLISHING
 BUFFING
 TUMBLING
 BURNISHING
 HONING
 LAPPING
 SUPER FINISHING OR MICROFINISHING

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 Thebelow table illustrates gradual improvement of
surface roughness produced by various processes
shown below.

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A process using very fine abrasive materials for
little or no material removal where visual
appearance is primary purpose.

 Forceper unit for polishing is the lightest of all the

processes that uses abrasives.

 Itis a surface finishing process performed by

special abrasive coated wheel, these wheels are
made of canvas, felt or wood.

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 OBJECTIVES
 THISPROCESS IS EMPLOYED FOR REMOVING
 SCRATCHES,TOOL MARKS.A VERY SMALL
AMOUNT OF METAL IS REMOVED.
 IRRESPECTIVE OF SHAPE IT IS USED FOR
ACCURACY AND SURFACE FINISH.
 POLISHING IS OFTEN USED TO ENHANCE THE
LOOKS OF AN ITEM, PREVENT CONTAMINATION
OF MEDICAL INSTRUMENTS, REMOVE OXIDATION,
CREATE A REFLECTIVE SURFACE, OR PREVENT
CORROSION IN PIPES.

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 Belowis an example of hand metal polishing using a
wheel with an abrasive belt.

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 In metallographic and metallurgy, polishing is
used to create a flat, defect-free surface for
examination of a metal's microstructure under a
microscope.
 Polishing may be used to enhance the looks of

certain parts on cars, motorbikes, handrails,

cookware, kitchenware, and architectural metal
applications.
 Pharmaceutical, dairy, and water pipes are buffed

to maintain hygienic conditions and prevent

corrosion. Buffing is used to manufacture of high-
quality lighting reflectors.

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THIS A PROCESS OF
OBTAINING A VERY FINE
SURFACE FINISH, HAVING A
“GRAINLESS” APPEARANCE ON
METAL OBJECTS.

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BUFFING TYPICALLY USES A CLOTH WHEEL AND
VERY FINE ABRASIVE.

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 Using cloth wheels combined with compounds, buffing
is a final mechanical finish that results in a mirror
bright to near mirror bright finish, depending upon
the base metal and/or prior mechanical finishing
steps.

 Buffing does not remove a large amount of metal and,

therefore, is sometimes applied after a plating
process.
 There are stages in buffing process-typically coarse,
medium and fine, each using a style of buffing wheel
and different types of compounds.

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 Tumbling is used to burnish, deburr, clean, radius, de-
flash, descale, remove rust, polish, brighten, surface
harden, prepare parts for further finishing, and break
off die cast runners.
 The process is fairly simple: a horizontal barrel is

filled with the parts which is then rotated.

 Variations of this process usually include media,

water, or other lubricants.

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Tumbling is an economical finishing
process because large batches of parts
can be run with little or no supervision
by the operator.
A full cycle can take anywhere from 6

to 24 hours with the barrel turning at

20 to 38 RPM.
In a wet processes a compound,

lubricant, or barreling soap is added to

aid the finishing process, prevent
rusting, and to clean parts.
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 Tumbling is usually most efficient with
the barrel half full.
 The disadvantages of this process are
that the abrasive action cannot be
limited to only certain areas of the part,
cycle times are long, and the process is
noisy.
Centrifugal barrel tumbling uses as
tumbling barrel at the end of a
rotating arm to add centrifugal forces
to the barreling process. This can
accelerate the process 25 to 50 times.
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 The burnishing process consists of pressing
hardened steel rolls or balls into the surface of the
work piece and imparting a feed motion to the
same.
 During burnishing considerable residual

compressive stress is induced in the surface of the

work piece and thereby fatigue strength and wear
resistance of the surface layer increase.

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17
 Ball burnishing is also used as a deburring
operation. It is especially useful for removing the
burr in the middle of a through hole that was
drilled from both sides.
 Roller burnishing, or surface rolling, is used on

cylindrical, conical, or disk shaped work pieces.

The tool resembles a roller bearing, but the
rollers are fixed so they slide against the
workpiece surface instead of rolling. It is
simultaneously rotated and pressed into the
workpiece. Typical applications for roller
burnishing include hydraulic system components,
shaft fillets, and sealing surfaces.
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 Honing is a finishing process, in which a tool called
hone carries out a combined rotary and reciprocating
motion while the work piece does not perform any
working motion.
 Most honing is done on internal cylindrical surface,

such as automobile cylindrical walls.

 The honing stones are held against the work piece

with controlled light pressure. The honing head is not

guided externally but, instead, floats in the hole, being
guided by the work surface.

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 Honing tool
IT IS REQUIRED
THAT-
Honing head
1. Honing stones
should not leave
the work surface

2. Stroke length
must cover the
entire work length.
Workpiece
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 Super abrasive honing stick with monolayer
configuration , where a layer of cBN grits are
attached to stick by a galvanic ally deposited metal
layer, is typically found in single stroke honing
application.
 The important parameters that affect material

removal rate (MRR) and surface roughness (R) are:

(i) unit pressure, p
(ii) peripheral honing speed, Vc
(iii) honing time, T

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 Lapping is regarded as the oldest method of obtaining
a fine finish. Lapping is basically an abrasive process
in which loose abrasives function as cutting points
finding momentary support from the laps.
 Characteristics of lapping process:

 Use of loose abrasive between lap and the

work piece
 Usually lap and work piece are not
positively driven but are guided in contact
with each other

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Figure schematically represents the lapping process.
Material removal in lapping usually ranges from 0.003 to
0.03 mm but many reach 0.08 to 0.1mm in certain cases.
Cast iron is the mostly used lap material. However, soft steel,
copper, brass, hardwood as well as hardened steel and glass
are also used.

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 In compared to grinding and honing, lapping is
minimal material removal, forces are very light and
parts move freely between lap plates.
 Finishes are measured in micron and nanometer
ranges. the term is also commonly used for processes
that produce very fine finishes using very loose
abrasive grains.
 Lapping operation is done with hand or machine.
 Lapping action is either rotary or reciprocating.
 Abrasive materials used include emery, corundum,
Iron oxide, chromium oxide, etc. mixed with a fluid
medium ,usually oil is used in this operation.

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  Figure illustrates
super finishing
end-face of a
cylindrical work
piece. In this both
feeding and
oscillation of the
super finishing
stone is given in
the radial
direction.
super finishing of end face of a cylindrical work piece in
radial mode
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 Figure shows the
super finishing
operation in plunge
mode. In this case
the abrasive stone
covers the section
of the work piece
requiring super
finish. The abrasive
stone is slowly fed
in radial direction
while its oscillation
is imparted in the
axial direction.

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  Super finishing
Abrasive tool rotating and can be
effectively
oscillating about a
done on a
stationary workpiece stationary
work piece as
shown in Fig. In
this the
abrasive stones
are held in a
disc which
oscillates and
rotates about
the axis of the
work piece.

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