Experimental Study on Surface Roughness and Flatness in Lapping of AISI 52100 Steel
الموضوعات :Masoud Farahnakian 1 , H. ُُShahrajabian 2
1 - Faculty of Engineering, Mechanical Engineering Department
Najafabad branch, Islamic Azad University, Iran
2 - Faculty of Engineering, Mechanical Engineering Department
Najafabad branch, Islamic Azad University, Iran
الکلمات المفتاحية: Lapping, Flatness, Surface Roughness, ANOVA, Hardened steel,
ملخص المقالة :
Lapping is one of the most important polishing processes which can be used to fabricate flat and smooth surfaces. In this paper, the effect of lapping characteristics and mesh number of abrasive particles are studied on the surface roughness and flatness for the machining of hardened AISI 52100 rings. The most significant lapping characteristics are pressure, lap plate speed and time. Scanning electron microscopy and optical microscopy are used to investigate micro cracks and surface textures. Results showed that surface roughness increased by rising the lapping pressure and plate speed. Also, reduction of the lapping time and mesh number of abrasive particles led to lower surface roughness. Application of lapping process decreased the flatness to 1.2 µm and surface roughness (Ra) from 0.58 to 0.051 µm. The lapping pressure was a significant factor on the surface roughness; and the lapping time was a significant factor on flatness. However, surface roughness increased with rising of mesh number and lapping time, and increased with decreasing the lapping pressure. The minimum surface roughness was 0.051 μm which was obtained in lapping pressure of 7 kPa, lapping speed of 0.164 m/s, time of 15 min and mesh number of 600.The flatness decreased with lapping speed, and reduced with increasing the pressure, mesh number and lapping time.
[1] Chen, C., Sakai, S., Inasaki, I., “Lapping of advanced ceramics”و Materials and Manufacturing Processes, Vol. 6, No. 2, 1991, pp. 211-226.
[2] Molenda, J., Charchalis, A., “Dependence between workpiece material hardness and face lapping results of steel C45”, Solid State Phenomena., Vol. 220-221, 2015, pp. 743-748.
[3] Kim, H. M., Park, G. H., Seo, Y. G., Moon, D. J., Cho, B. J., and Park, J. G., “Comparison between sapphire lapping processes using 2-body and 3-body modes as a function of diamond abrasive size ”, Wear., Vol. 332-333, 2015, pp. 794-799.
[4] Bulsara, V. H., Ahn, Y., Chandrasekar, S., and Farris, T. N., “Polishing and lapping temperature”, Trans. ASME J. Tribol., Vol. 119, 1997, pp. 163-170.
[5] Chang, Y. P., Dornfeld, D. A., “An investigation of the AE signals in the lapping process”, Annals CIRP., Vol. 45, 1996, pp. 331-334.
[6] Uhlmann, E., Ardelt, T., “Influence of kinematics on the face grinding process on lapping machines”, Annals CIRP., Vol. 48, No. 1, 1999, pp. 281-284.
[7] Guzzo, P. L., De Mello, J. D. B., and Daniel, J., “Effect of crystal orientation on lapping and polishing processes of natural quartz, IEEE Trans. Ultrasonics Ferroelectrics Frequency Control”, Vol. 47, 2000, pp. 1217-1227.
[8] Mamalis, G., Hidasi, B., Dudas, Z., and Branis, A. S., “On the Lapping Mechanism of Sintered A12O3 Ceramic Surfaces Using Diamonds”, Materials and Manufacturing Processes, Vol. 15, No. 4, 2000, pp. 503-520.
[9] Chang, K. Y., Song, Y. H., and Lin, T. R., “Analysis of Lapping and Polishing of a Gauge Block”, Int J Adv Manuf Tech., Vol. 20, 2002, pp. 414-419.
[10] Tam, H. Y., Cheng, H. B., and Wang, Y. W., “Removal rate and surface roughness in the lapping and polishing of RB-SiC optical components,” J Mat Process Tech., Vol. 192-193, 2007, pp. 276, 280.
[11] Belkhir, N., Bouzidd, D., Herold, V., “Correlation between the surface quality and the abrasive grains wear in optical glass lapping”, Tiribology International., Vol. 40, 2007, pp. 498-502.
[12] Deshpande, L. S., Raman, S., Sunanta, O., and Agbaraji, C., “Observations in the flat lapping of stainless steel and bronze”, Wear., Vol. 265, 2008, pp. 105-116.
[13] Mohan, R., Ramesh Babu, N., “Experimental investigations on ice bonded abrasive polishing of copper materials”, Materials and Manufacturing Processes., Vol. 25 , No. 12, 2010, pp. 1462-1469.
[14] Mohan, R., Ramesh Babu, N., “Design, development and characterization of ice bonded abrasive polishing process”, International Journal of Abrasive Technology., Vol. 4 , No. 1, 2011, pp. 57-76.
[15] Mohan, R., Ramesh Babu, N., “Ultrafine finishing of metallic surfaces with the ice bonded abrasive polishing process”, Materials and Manufacturing Processes., Vol. 27, 2012, pp. 412-419.
[16] Tsai, M. Y., Chen, C. Y., and He, Y. R., “Polishing Characteristics of Hydrophilic Pad in Chemical Mechanical Polishing Process”, Materials and Manufacturing Processes., Vol. 27, 2012, pp. 650-657.
[17] Tian, Y. B., Zhong, Z. W., Lai, S. T., and Ang, Y. J., “Development of fixed abrasive chemical mechanical polishing process for glass disk substrates”, Int J Adv Manuf Tech., Vol. 68, 2013, pp. 993-1000.
[18] Dong, Z., Cheng, H., “Study on removal mechanism and removal characters for SiC and fused silica by fixed abrasive diamond pellets”, Int J. Mach. Tool Manuf., Vol. 85, 2014, pp. 1-13.
[19] Sushil, M., Vinod, K., and Harmesh, K., “Experimental Investigation and Optimization of Process Parameters of Al/SiC MMCs Finished by Abrasive Flow Machining”, Materials and Manufacturing Processes., Vol. 30, 2015, pp. 902-911.
