PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar • Gill • Smid

Surface Finishing Processes

Unit 26

Copyright © The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.
 26-2

Objectives
• Identify and explain the purposes of surface
finishing processes
• Explain the benefits of honing
• Be familiar with oxide coatings and their
purposes
 26-3

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, and tumbling
 26-4

Burnishing
• Cold-working process that sizes, finishes and
work hardens internal and external metal
surfaces of pressure contact of hardened rools
• Process displaces peaks and valleys of
irregular height
• Burnishing tool incorporates planetary system
of tapered rolls evenly spaced by retaining
cage
 26-5

Burnishing Process
• Hardened mandrel forces burnishing tool
against surface of part
– Mandrel tapered inversely to taper of rolls
• Tool is adjusted slightly larger than part
• Slight pressure created when tool passes
through part
– Exceeds yield point of softer part surface
• Results in mirrorlike, tough, wear and
corrosion-resistant surface
 26-6

Electropolishing
• Referred to as reverse plating
• Uses combination of rectified current and
blended chemical electrolyte bath
• Removes flaws from surface of metal parts
• Benefits include bright finish, deburring, size
control, and microfinish improvement
 26-7

Electropolishing Process
Rack of titanium, copper,
or bronze holds parts
Power (positive charge)
Source - +

Cathode plate: Lead, Chemical bath

Copper, or Stainless steel
(negative charge) Tank fabricated from steel
and rubber-lined
1. Metal part is charged positive and immersed.
2. Current applied and electrolyte allows metal ions to be
removed from part.
3. Electrolyte maintains dissolved metals in solution.
4. When process completed, part run through cleaning
and drying
 26-8

Honing
• Abrasive finishing operation
• Small amount of stock removed from internal
or external surface of part
• Improves flatness and surface finish
• Low speed operation
– 85 to 300 sf/min or 25 to 95 m/min
 26-9

Differences Between
Honing and Grinding
• Honing is low-speed operation
– 85 to 300 sf/min, or 25 to 95 m/min
• Grinding is high-speed operation
– 5000 to 6500 sf/min, or 25 to 33 m/min

Copyright © The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.
 26-10

Grinding

Grinding tends to cause

thermal damage to surface
of workpiece, often to
depth of up to .002 in.
(0.05 mm) or more.
Chips produced are short,
hot sparks due to intermittent
contact of each abrasive
particle on workpiece surface.
 26-11

Honing
Gentle, cooler finishing
operation, with little or
no damage or distortion
of the workpiece surface.

Continuous cooler chip produced

due to continuous contact of abrasive
hone with the workpiece.
 26-12

Types of Honing Processes

• Conventional
– Cutting pressure applied when mandrel forces stone and
guide-shoe surfaces into contact with bore
• Rotational and reciprocal action of hone causes thousands of small
cutting edges on stone to shear minute chips from workpiece

• Single-stroke
– Expandable, diamond-plated abrasive sleeve on tapered
arbor expanded to size by calibrated adjusting screw
– Faster than convention honing and maintains consistent
size
 26-13

Various Honing Stones

Single-stone hones used on
small bores less than 3.00 in.

Four-point-contact hones are

capable of fast metal removal

Multi-point-contact hones used

on production for honing large
parts.
Copyright © The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
 26-14

Machine Requirements
• For fullest potential of superabrasives (CBN)
– Be rigid, no spindle vibration, and sufficient
power for high material-removal rates
– Have high-spindle speeds—about three times
speed for conventional hones and closely
controlled increments of stone feed and pressure
– Have coolant system capable of supplying
adequate volumes of filtered honing fluids
 26-15

Honing Guidelines

• Considerations for selecting proper CBN

(Cubic Boron Nitride) hone
– Type and hardness of the work material
– Amount of material to be removed
 26-16

General Rules
for any CBN Hone
• For maximum removal rates, use coarse grit sizes,
lower concentration, and narrow stones at high
speed.
• For fine finishes, use fine grit sizes and higher
concentrations.
• For hard materials, use a soft bond; for soft
materials, use a hard bond.
• Always use an adequate supply of coolant to clean
the stone, clear the chip, and cool the workpiece.
 26-17

Tumbling
• Used for cleaning, polishing and removing
sharp corners and burrs from metal parts
• Economical since material handled in bulk
• Various sizes available of tumbling barrels
– Material and shape of part to be cleaned
– Depth and hardness of scale or rust
– Previous finish to be removed
 26-18

Selecting the Equipment

and Tumbling Media
• Must choose: proper type of barrel, abrasive,
lubricant, and ratio of work to total volume of
batch and barrel
• Surfacing operations range from deburring
and polishing to honing and mirror finishing
• Common abrasives: aluminum oxide,
ceramic, plastic, stone chips, crushed
corncob, and steel balls
 26-19

The Tumbling Process

• Parts loaded into suitable tumbling barrel
and appropriate tumbling media added
• Water level in loaded barrel bears definite
relation to type of finish desired
– Burnishing: level just above top line of loading
– Honing and light deburring: level 1/3 to halfway
below load line
– Fast deburring: level 2/3 or even lower below
load line
 26-20

Black-Oxide Coatings
• Chemical conversion process produced by
reaction of iron in ferrous metal with
oxidizing salts present in black oxide
• Salts include penetrates, catalysts, activators
and proprietary additives
• Result is formation of black iron oxide,
magnetite on surface of metal
• Used for decorative and corrosion prevention
 26-21

Black-Oxide Process
• Can be produced of ferrous metal using
– Molten salt bath (600ºF and above)
– Cold black solution at room temperature
– Hot alkaline aqueous solution (285ºF and 300ºF)
• Hot alkaline aqueous most commonly used
– Produces deep black consistent and uniform
finish
– Penetrates into metal surface up to 5 to 10
millionths of an inch