Superfinishing Method

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Surface Finishing Method 1 1.  Machined component surfaces are comprised of parallel lines of “peaks” and “valleys” arranged in a generally periodic or sinusoidal pattern.  This surface roughness and surface texture is generated by the tool path and the abrasive cutting stone of the machine tool.
Surface Finishing Method 2 2.  When the component is introduced into REM’s chemically accelerated surface finishing process, the alloy matched “active” processing compound reacts to form a self-assembling monolayer (or conversion coating) on the surface of the metal component.

  • This self-assembling monolayer/conversion coating is a self-limiting metal complex that is softer than the base metal and is more easily removed than the base metal.
Surface Finishing Method 3 3.  The physical/mechanical interaction of the media in the processing apparatus wipes away this conversion coating from all accessible areas exposing the base metal to the chemical reaction again.
4.  The conversion coating reforms on the newly exposed metal surfaces and the process is repeated; areas that are not accessible to the media are not affected and thus, no material is removed from these areas.

  • In the early stages of the process, material is only removed from the peaks, as the valleys are not currently accessible to the media.
Surface Finishing Method 5 5.  The peak height and valley depth is reduced as the peaks are transformed into plateaus as the surface is being flattened/planarized.
Surface Finishing Method 6 6.  The process continues and the surface roughness continues to be reduced while the bearing ratio is increased as the plateaus begin to reach the bottom of the valleys; this is known as the “Refinement Step” of the process.
Surface Finishing Method 7 7.  Once the desired surface finish and/or amount of material removal is achieved, the process is transitioned from the “Refinement Step” to the “Burnishing Step”.  The active processing compound dosing is stopped and an alkaline cleaning compound is dosed into the processing apparatus to removal residual conversion coating from the component and to aid in visually brightening its surface.
Surface Finishing Method 8 8.  Once the desired level of cleanliness and/or brightness is achieved, the process is complete and the component(s) can be removed from the processing apparatus.

 

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