Super finishing

Super finishing
Super finishing is a operation using bonded abrasives stones in a particular way to produce an extremely high quality of surface finish in conjunction with almost complete absence of defects in the surface layer. A very thin layer of metal (0.005 to 0.02 mm) is removed in super finishing. Superfinishing, also known as micromachining and short-stroke honing. Common abrasives used for superfinishing include aluminium oxide, silicon carbide, cubic boron nitride (CBN) and diamond.

 This operation may be applied for external and internal surfaces of parts made with steel, cast iron and non ferrous alloys, which have previously been ground or precision turned.

Process
In superfinishing, a very fine grit (grain size 400 to 600) abrasive is retained in a suitable holder to the surface of the work piece with a light spring pressure. The stick is given a feeding and oscillation motion, and the work piece is reciprocated or rotated according to the requirements of the shape being super finished. In this process, the work rotational speed is low (2 to 20m/min) the longitudinal feed changes rapidly in short strokes (2 to 5 mm) with frequency from 500 to 1800 strokes per minute and the springs hold the stick against the work with a force from 2 to 10 kgs.

 A special lubricant, usually a mixture of kerosene and oil is used to obtain a high quality of surface finish. Special general purpose machine tools are available for super finishing. Other types of ordinary machine, in particular, lathes are sometimes employed for this purpose. Single purpose machine tools for example, for finishing crankshafts journals, camshafts etc are also used.

Types
There are three types superfinishing: Through-feed, plunge, and wheels.

Through-feed This type of superfinishing is used for cylindrical workpieces. The workpiece is rotated between two drive rollers, which also move the machine as well. Four to eight progressively finer abrasive stones are used to superfinish the workpiece. The stones contact the workpiece at a 90 angle and are oscillated axially. Examples of parts that would be produced by process include tapered rolls, piston pins, shock absorber rods, shafts, and needles.
Plunge This type is used to finish irregularly shaped surfaces. The workpiece is rotated while the abrasive plunges onto the desired surface. Wheels Abrasive cups or wheels are used to superfinish flat and spherical surfaces. The wheel and workpiece are rotated in opposite directions, which creates the crosshatching. If the two are parallel then the result if a flat finish, but if the wheel is tilted slightly a convex or concave surface will form.

Advantages/ disadvantages
Advantages of superfinishing include: increasing part life, decreasing wear, closer tolerances, higher load bearing surfaces, better sealing capabilities, and elimination of a break in period. Disadvantage is that superfinishing requires grinding or a hard turning operation beforehand, which increases cost. Superfinishing has a lower cutting efficiency because of smaller chips and lower material removal rate. Superfinishing stones are softer and wear more quickly.

Applications
Common application include : steering rack components, transmission components, fuel injector components, camshaft lobes, hydraulic cylinder rods, bearing races, needle rollers, and sharpening stones and wheels. One of the most important application of superfinishing is finishing of precision gears.