Superfinishing with microabrasive film is a finishing system especially developed for the processing of cylindrical surfaces.
The demand for better surface finishes on the workpiece is forever increasing particularly in relation to precision applications and the wider variety of materials to be finished.
Up to the early 2000s, finishing using superfinishing stones was the preferred method to achieve precise surface finishes. Today, superfinishing with microabrasive film has set a new standard.
Technology and advantages of superfinishing with microabrasives film
Compared with traditional finishing systems, superfinishing with microabrasive film reduces machining times and provides a cost-effective production process whilst maintaining precise and consistent finishes over the entire surface irrespective of workpiece dimensions.
For this application, a specific machine known as a “Superfinisher” has been developed using microabrasive rolls which replace the use of polishing stones or abrasive belts. The rolls are mounted on the machine which presents the film to the work head via a feed roll: a receiving roll rewinds the used microabrasive film.
The new microabrasive film is slowly fed via the feeding roll; the feed rate can be incremental or continuous. The film makes contact with the workpiece either with a contact shoe or contact wheel, pressure being applied pneumatically. The process guarantees a consistent surface finish over the entire surface of the workpiece to be superfinished.
Unlike grinding and polishing, superfinishing can create a cross-hatch structure on the surface. It is possible to achieve reproducible high quality surface finishes on rotationally symmetrical workpieces on virtually any material composition.
An additional benefit of using the superfinishing process is improved workpiece geometry. When the abrasive makes contact with the workpiece, the high peaks are removed quickly. Depending on application, improved flatness, cylindricity and profile can be achieved and minted.
It is the consistency of the microabrasive product being used which largely dictates the consistency of the process.
Precision Polishing microabrasive rolls are manufactured in a stable production process using only high quality raw materials which ensures a predictable and repeatable surface finish.
Application and workpieces
As one of the final applications, superfinishing with microabrasive film is used after grinding, polishing or hard turning to remove high peaks or excess material created by the previous machining processes.
It improves surface finish and reduces the processing time. Pre-machined surfaces can be finished in a cost-effective way.
Typical applications include crankshafts, gravure rolls, film rolls, rubber rolls, bearing seats, sealing surfaces, pins, pneumatic pistons, gas spring pistons, hydraulic cylinders and piston rods and laser engraved surfaces.
Workpiece materials include, but not limited to: metals, hard chrome and carbide coatings, DLC, tungsten carbide, aluminum, copper, rubber, ceramics, plastics and others.
Precision Polishing supports their business partners and customers in identifying the most suitable microabrasive film to be used in relation to workpiece material, application process and surface finish requirements. We can also assist in the optimization of the machine and setting parameters. For more information, click here.
As stated above, superfinishing using microabrasive film makes it possible to achieve reproducible high-quality surface finishes on virtually any workpiece material.
Thanks to the consistency of Precision Polishing microabrasive film range, a surface finish of less than 0,010 Ra μm can be achieved by using a specified film quality and sequence of abrasive grit size.
The superfinishing process allows the user to achieve most surface finish requirements. The rough or high peaks are only removed from the surface and therefore it has no detrimental effect on workpiece geometry; in fact, this can also be improved.