Basic observations in the flat lapping of aluminum and steels using standard abrasives

• Published in: International journal of advanced manufacturing technology Vol. 44; no. 3-4; pp. 293 - 305
• Main Authors: Agbaraji, Casmir, Raman, Shivakumar
• Format: Journal Article
• Language: English
• Published: London Springer-Verlag 01.09.2009; Springer Nature B.V
• Subjects: Abrasive finishing; Abrasives; Aluminum oxide; Austenitic stainless steels; CAE) and Design; Coefficient of friction; Computer-Aided Engineering (CAD; Engineering; Industrial and Production Engineering; Material removal rate (machining); Mechanical Engineering; Media Management; Original Article; Scanning electron microscopy; Silicon carbide; Stainless steel; Statistical methods; Substrates; Surface finish; Variance analysis; Workpieces; Surface finish; Embedding; Material removal; Redox chemistry; Lapping
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-008-1827-4

This research studies the characteristics of aluminum 2024, 304 stainless steel, and 1018 steel during lapping with three different types of abrasives, namely, garnet, silicon carbide, and white aluminum oxide, through detailed experimental analysis. Specifically, the effects of different abrasives on material removal rate and surface finish were evaluated. It was found that silicon carbide and white aluminum oxide abrasives removed more material per minute than garnet. A higher mean frictional force and mean coefficient of friction were obtained in aluminum lapped with SiC and white Al 2 O 3 abrasives, and a lower mean frictional force was obtained in 304 stainless steel lapped with SiC. From geometric and energy-dispersive spectroscopy analysis obtained using scanning electron microscopy, it was confirmed that some abrasives became embedded into the lapped metal substrates. No burn was observed on the lapped samples, and scratches and unfinished lapped parts were observed mainly in 304 stainless steel. In order to determine the quantitative influence of each variable, an analysis of variance was performed. It was found that the main effects of abrasive types, size of abrasives, and type of work material had statistically significant influence on material rate and surface finish. In addition, there was a highly significant two-way interaction between abrasives and workpiece.