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Manufacturing Processes-II

5th sem Mechanical


Section -II
Sub Topic
Chapter 7: Metal Finishing and
Coating
Surface Finishing Processes

gradual improvement of surface roughness produced by various processes ranging from


precision turning to superfinishing including lapping and honing.
Surface Finishing Processes

Improve appearance and sales value of


product
Used to resist wear, electrolytic
decomposition, and corrosive wear
Treatment process (chemical or electrical)
produces oxide of original metal on surface
Common methods: burnishing,
electropolishing, honing etc.
26-3
Processes
Honing
Lapping
Polishing and Buffing
Super finishing
Honing
Honing
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
It is desired that
honing stones should not leave the work surface
stroke length must cover the entire work length.
Honing
Honing
Honing is a finishing process performed by a honing tool, which contains a
set of three to a dozen and more bonded abrasive sticks. The sticks are
equally spaced about the periphery of the honing tool. They are held against
the work surface with controlled light pressure, usually exercised by small
springs.
The honing tool is given a complex rotational and oscillatory axial motion,
which combine to produce a crosshatched lay pattern of very low surface
roughness

Honing tool
Honing
Abrasive process performed by a set of bonded abrasive
sticks using a combination of rotational and oscillatory
motions
Common application is to finish the bores of internal
combustion engines
Grit number (grain size) range between 30 (medium) and 600
(very fine) (the smaller grain size, the larger grit number)
Surface finishes of 0.12 m (5 -in) or better
Creates a characteristic cross-hatched surface that retains
lubrication
Honing

Figure 25.16 The honing process: (a) the honing tool used for internal bore surface,
and (b) cross-hatched surface pattern created by the action of the honing tool.
Honing Tool

Figure : Schematic illustration of a honing tool used to improve the surface


finish of bored or ground holes.
Honing
Honing
Honing
Stone

Al2O3 or SiC bonded abrasives

The critical process parameters are:

Rotation speed

Oscillation speed

Length and position of the stroke

Honing stick pressure

Parameters that affect material removal rate (MRR) and surface roughness (R) are:

Unit pressure, p

Peripheral honing speed, Vc

Honing time, T
Lapping
Lapping
Lapping
In lapping, instead of a bonded abrasive tool, oil-based fluid suspension of
very small free abrasive grains (aluminum oxide and silicon carbide, with
typical grit sizes between 300 and 600) called a lapping compound is applied
between the work piece and the lapping tool.
The lapping tool is called a lap, which is made of soft materials like copper,
lead or wood. The lap has the reverse of the desired shape of the work part.
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 accomplish
the process with greater consistency and efficiency.
Lapping
Lapping
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. Material
removal in lapping usually ranges from .003 to .03 mm but many reach
0.08 to 0.1mm in certain cases.
The cutting mechanism in lapping is that the abrasives become embedded
in the lap surface, and the cutting action is very similar to grinding, but a
concurrent cutting action of the free abrasive particles in the fluid cannot be
excluded.
Lapping is used lo produce optical lenses, metallic bearing surfaces, gages,
and other parts requiring very good finishes and extreme accuracy.
Lapping
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

Relative motion between the lap and the work should change continuously
so that path of the abrasive grains of the lap is not repeated on the work
piece.
Lapping
Uses fluid suspension of very small abrasive particles between
workpiece and lap (tool)
Lapping compound (fluid suspension) - fluid with abrasives,
general appearance of a chalky paste
Typical grit sizes (Grit number) between 300 (medium) to 600
(very fine)
Applications: optical lenses, metallic bearing surfaces, gages
The same as polishing samples for microscopic or electronic
microscopic tests
Lapping

Figure : The lapping process in lens-making.


Lapping

Figure : (a) Schematic illustration of the lapping process. (b) Production


lapping on flat surfaces. (c) Production lapping on cylindrical surfaces.
Lapping
Lapping

Schematics of lapping process showing the lap and the cutting action of suspended
abrasive particles.
Lapping
Lapping

Figure (a) Schematic illustration of the lapping process. (b) Production lapping on
flat surfaces.(c) Production lapping on cylindrical surfaces.
Lapping
Abrasives of lapping
Al2O3 and SiC, grain size 5~100m
Cr2O3, grain size 1~2 m
B4C3, grain size 5-60 m
Diamond, grain size 0.5~5 V
Lubricating materials of lapping
Machine oil
Rape oil
grease
Technical parameters affecting lapping processes are
unit pressure
the grain size of abrasive
concentration of abrasive in the vehicle
lapping speed
Buffing
Buffing
Polishing
Polishing is a finishing operation to improve the surface finish by means of a
polishing wheel made of fabrics or leather and rotating at high speed. The abrasive
grains are glued to the outside periphery of the polishing wheel. Polishing operations
are often accomplished manually.
Buffing
Buffing is a finishing operation similar to polishing, in which abrasive grains are not
glued to the wheel but are contained in a buffing compound that is pressed into the
outside surface of the buffing wheel while it rotates. As in polishing, the abrasive
particles must be periodically replenished.
As in polishing, buffing is usually done manually, although machines have been
designed to perform the process automatically.

Buffing wheels are made of discs of linen, cotton, broad cloth and canvas
Buffing
Buffing
Super Finishing
Super Finishing
Super finishing

Super finishing is a micro finishing process that produces a controlled surface


condition on parts which is not obtainable by any other method. The operation which
is also called micro stoning consist of scrubbing a stone against a surface to produce
a fine quality metal finish.

The process consists of removing chatter marks and fragmented or smear metal from
the surface of dimensionally finished parts. As much as 0.03 to 0.05 mm of stock can
be efficiently removed with some production applications, the process becomes most
economical if the metal removal is limited to 0.005 mm
Super Finishing
Similar to honing - uses bonded abrasive stick pressed
against surface and reciprocating motion
Differences with honing:
Shorter strokes
Higher frequencies
Lower pressures between tool and surface
Smaller grit sizes
Super Finishing

Figure : Superfinishing on an external cylindrical surface.


Super Finishing

Figure : Schematic illustration of the superfinishing process for a cylindrical part.


(a) Cylindrical microhoning. (b) Centerless microhoning.
Super Finishing
Super finishing

Figure Schematic illustrations of the super finishing process for a cylindrical part. (a)
Cylindrical mircohoning, (b) Centerless microhoning.
Surface Treatment
Introduction
Surface Treatments
Why?
Type
Why use a surface treatment?
Improves durability

Controls Friction

Reduces Adhesion
Why use surface treatment?
Improves Lubrication

Rebuild Surfaces

Aesthetics
Types of Treatments
Mechanical Surface Treatments
Mechanical Plating & Cladding
Case Hardening
Thermal Spraying
Vapor Deposition
Laser Treatments
Mechanical Surface Treatments
Peening
Shot Peening
Laser Shot Peening
Water-jet Peening
Ultrasonic Peening

Roller Burnishing

Explosive Hardening
Mechanical Plating & Cladding
Mechanical Plating

Cladding
Laser Cladding
Case Hardening and Hard Facing

Case Hardening

Hard Facing

Spark Hardening
Thermal Spraying
Combustion Spraying

Thermal Wire Spray

Thermal Metal-Powder
Spray

Plasma Spray
Vapor Deposition
Physical Vapor Deposition

Vacuum Deposition

Sputtering

Chemical Deposition

Ion Platting
Physical Vapor Deposition
Sputtering
Chemical Vapor Deposition

Thermochemical Process

Cutting Tools

Thicker

Tedious
Ion Implantation & Diffusion
Coating
Particulates penetrate substrate

Modifies surface properties


Increases hardness
Improves durability

Masking capability
Laser Treatments
Heating
Melting
Vaporization
Peening
Electroplating, Electroless Plating,
and Electroforming
Electroplating
Workpiece (cathode) is
plated with other metal
(anode) through a water-
based electrolytic solution
A SLOW Process!!!
75 micrometers/hour
Solution must be replenished
Sacrificial anode
Additional salts of metal
Electroplating, Electroless Plating,
and Electroforming
Operation Sequence
Chemical Cleaning
Acid Bath
Application of a Base Coat
(Optional)
Final Electroplating
Rinse Tanks

Common Plating Metals


Nickel
Cadmium, Copper
Tin, Zinc
Electroplating, Electroless Plating,
and Electroforming

Electroless Plating
Chemical Reaction
More Expensive $$
Uniform Thickness

Electroforming
Metal-fabrication
Metal electrodeposited on a
mandrel
Conversion Coatings
Anodizing-
The workpiece is the
anode in an electrolytic
cell

Coloring-
Alters color of metals,
alloys, and ceramics
Conversion of surfaces
into chemical
compounds: oxides,
chromates, and
phosphates
Hot Dipping
Workpiece is dipped into
molten metal
Zinc- galvanized-steel sheet
Tin- food containers

Hot-dipped Galvanizing line


Porcelain Enameling; Ceramic and Organic
Coatings
Enamels- fuse a coating material by
heating to 425 to 1000.

Ceramic coatings- Intense temp


applied

Organic coatings- Wide range of


properties: flexability, durability,
color, texture
Diamond Coating and Diamond-Like
Carbon
Techniques
Chemical vapor
deposition
Plasma-assisted vapor
deposition
Ion-beam-enhanced
deposition
Diamond Properties
Hardness, wear
resistance, thermal
conductivity
Surface Texturing & Painting
Texturing Techniques
Etching
Electric Arcs
Lasers
Atomic oxygen

Paint Classification
Enamels
Lacquers
Water-based paints
What is Galvanizing?
The process of
galvanizing consists
of coating metals,
such as iron, with a
thin protective layer of
zinc.
The zinc layer
provides protection to
Before & After the metal from
Hot Dip Galvanizing
corrosion.
Cathodic Protection

The steel is protected by the


surrounding zinc even if it is scratched.
How Does Zinc Protect The Underlying Iron Surface?
Zinc coatings prevent corrosion of the protected metal by forming a
barrier, and by acting as a sacrificial anode if this barrier is damaged.

When exposed to the atmosphere,


zinc reacts with oxygen to form zinc
oxide, which further reacts with
water molecules in the air to form
zinc hydroxide.
Finally zinc hydroxide reacts with
carbon dioxide in the atmosphere
to yield a thin, impermeable,
tenacious and quite insoluble dull
gray layer of zinc carbonate which
adheres extremely well to the
underlying zinc, so protecting it
from further corrosion.
The oxidation of zinc is more likely than the oxidation of iron.

*
*

These potentials indicate the relative thermodynamic


tendency for the indicated half-reaction to occur.
Zn <--> Zn+2 + 2 e E = 0.763 volts
Fe <--> Fe+2 + 2 e E = 0.409 volts
Anodizing
Purpose of Anodizing
Grow an aluminum oxide layer on the aluminum so it can
be dyed
Corrosion and wear resistance
Hardening (Type III)
Color cosmetic
Overview
Aluminum part immersed in acid electrolyte
Apply electrical current, DC, ~12V
The part is the anode (+) (thus the name)
Electrolysis and chemical reaction occurs
Porous aluminum oxide layer grows on the aluminum
Up to 3000 times thicker than naturally occuring
Al2O3 layer
Dye goes into pores, results in bright colors
Place in boiling water to seal pores
Electrochemistry
Electrolyte in Solution: Free ions ,conductive
Sulfuric, oxalic, or phosphoric acid typically used
15% solution of sulfuric acid (H2SO4)
Electrolysis: Extracts constituent elements from
solution
Anode
Evolution of oxygen
2Al + 3H20 Al203 + 6H+ + 6e-
Cathode
Evolution of hydrogen
6H20 + 6e- 3H2 (g) + 6OH-
Pore growth
Acid electrolyte acts as solvent for oxide
Dissolves portions of barrier oxide layer
Oxide grows at metal/oxide interface
Rate of growth dependent on current, concentration,
temperature, voltage
Hexagonal shape
Anodizing Setup
Materials

Aluminum item (anode)


Aluminum wire
Aluminum sheet (cathode)
Sulfuric Acid 15%
Non-metal container
Power supply
Distilled/de-ionized water
Dye (RIT clothes dye)
Baking soda
Process
Anodizing Tank
Results
Anodizing in General
Other metals that can be anodized
Titanium, magnesium, niobium, tantalum,
tungsten, zirconium
Ti utilizes interference property of oxide film
instead of dye for color
History
Anodizing developed around 1917 with first US
patent in 1925 (*AAA)

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