Machining Process-Ii: (Assignment)

University Of Engineering and
Technology
Industrial and Manufacturing
Department
MACHINING
PROCESS-II
(Assignment)
Submitted To:
Miss Sana Ehsan
Submitted By:
H.M.Asad Ali
(2011-IM-77)
Initial and final surface preparation

techniques.
What is Initial Surface Preparation?
Initial Surface preparation is the essential first stage treatment of a metal workpiece
before the application of any coating & other kind of machining process, and is
generally accepted as being the most important factor affecting the total success of
a Post Machining Process.
What are the main types of Initial Surface Preparation?
There is a wide range of surface treatments available. Techniques can be classified
into five groups, according to the nature of treatment:
1.
2.
3.
4.
5.
Cleaning/Degreasing
Surface Roughing
Chemical Treatments
Physical Treatments
Primers
1. Cleaning/Degreasing:
Removal of loose solids can be accomplished with a clean brush or blast of clean,
dry air. Organic solvent or alkaline aqueous solution removes organic materials such
as grease, oil and wax from metal Work piece surfaces. This can be accomplished by
wiping, dipping or spraying.
2. Surface Roughening:
Techniques where abrasive materials are employed to remove unwanted layers and
generate a roughened surface texture.
3. Chemical Treatments:
Immersion of the metal Work piece in an active solution which has the power to
etch or dissolve a part of the metal Work piece surface or change it in such a way
that the treated surface becomes chemically active. An electrochemical reaction
can also be included where current is transferred through an electrolyte between an
auxiliary electrode and the metal Workpiece surface, e.g. anodizing, and this
introduces several additional factors to be controlled.
4. Physical Treatments:
Techniques where the metal Work piece surface is cleaned and chemically modified
by exposure to excited charges or species. Techniques such as corona discharge,
plasma, flame or exposure to ultraviolet/ozone are examples in this group.
5. Primers:
Alternative surface treatments, often simpler than chemical or physical methods,
applied by dipping, brush or spray. They can chemically alter the surface (e.g. silane
coupling agents, chromate conversion coatings), or protect the preferred surface
already generated by another method (e.g. aerospace primers after anodizing).
Finishing Surface Techniques:
As the name of this group of abrasive operations suggests, their objective is to
achieve superior surface finish up to mirror-like finishing and very close dimensional
precision. The finishing operations are assigned as the last operations in the single
part production cycle usually after the conventional or abrasive machining
operations, but also after net shape processes such as powder metallurgy, cold
fleshless forging, etc.
Main types of Finishing Surface Techniques:
1.
2.
3.
4.
honing,
lapping,
super finishing,
polishing, and buffing
1. 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
2. Lapping:
In lapping, instead of a bonded abrasive tool, oil-based fluid suspension of very
small free abrasive grains (aluminum oxide and silicon carbide) called a lapping
compound is applied between the workpiece 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 workpiece. To accomplish
the process, the lap is pressed against the work and moved back and forth over the
surface in a figure-eight or other motion pattern, subjecting all portions of the

surface to the same action.
3. Super
finishing:
Super
finishing is a
finishing
operation
similar to honing, but it involves the use of a single abrasive stick. The reciprocating
motion of the stick is performed at higher frequency and smaller amplitudes. Also,
the grit size and pressures applied on the abrasive stick are smaller. A cutting fluid
is used to cool the work surface and wash away chips.
4. Polishing and buffing:

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 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.

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University Of Engineering and

Initial and final surface preparation

surface in a figure-eight or other motion pattern, subjecting all portions of the

4. Polishing and buffing:

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