STUDY OF STOCK REMOVAL RATE OF WHITE CERAMIC IN SINGLE SIDE LAPPING PROCESS WITH EXTERNAL DRIVE

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STUDY OF STOCK REMOVAL RATE OF WHITE CERAMIC IN SINGLE

SIDE LAPPING PROCESS WITH EXTERNAL DRIVE

Mayur P. Patil

Mechanical Eng., Bharat College of Engineering, Mumbai University, Maharashtra,India.

ABSTRACT

Lapping is a critical technology in a number of precision manufacturing applications. It is time consuming; so it is difficult to attain higher production rate in lapping. In my previous paper (study) the result &relationship of SRR & RPM shown in which lapping is carried by due to surface contact force in between specimen & lap plate.Here to check the improvement in methodology of lapping process to enhance Stock Removal rate some testings are carried out with attachment of external drive(external force to retainer ring). It is carried out on White Ceramic (White Alumina) with hardness 6 mho.In this study the considered affecting parameters are Direction of retainer rings, RPMs oflap plate & retainer ring, dead weights& External drive.This External drive has been newly added as an improvement than the previous one.

KEYWORDS: SRR(Stock Removal Rate),dead weights, RPM (Revolution per minute).

INTRODUCTION

Lapping is the one of important& costly process of engineering.Due to the higher

operation time;cost is high.Nowadays lapping is used in all engineering field of precision

manufacturing. It is useful for automobile spare parts, electronic component, diamond jewellery,

glass industry, pneumatic and hydraulic machinery and parts, aerospace engineering etc. The

existing systems have low production rate due to low SRR. So in this paper study of improved

process is elaborated. In this study of STOCK REMOVAL RATE of Lapping Process with

_{GE-International Journal of Engineering Research}

Vol. 5, Issue 2, February 2017 Impact Factor- 5.613 ISSN(O): 2321-1717, ISSN(P): 2394-420X

© Associated Asia Research Foundation (AARF) Publication

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external drive done .The results includesstock removal rate, flatness, surface finish.In lapping to

apply the vertical force on specimens to be lapped dead Weights are used.

METHODOLOGY

Here first of all the relation of rotational speeds between Lapping plate and Retainer ring

is accumulated [i.e.1]. To get the relation of Stock Removal Rate(SRR) number of tasting’s were

done. The external drive is provided to retainer ring so the rpm will be increased. The testings

are completed by variation of the combination of variation RPM of lap plate & dead weight.In

this process the Ceramic rings were used. The ceramic rings wereBefore lapping the rings are

thoroughly cleaned & numbered on inner side as well as outer side to get accurate readings &

results.

TESTING for SRR-

Specimen: Ceramic

Hardness: 6 mho Composition: White Alumina (95 %)

Internal Diameter: 13 mm Outer Diameters: 22 mm

Area: 2.474 mm2 Time: 15 min

Abrassive Flow Rate: 10 ml/sec Abrassive: Aluminium Oxide 15 micron Direction of Lap Plate: Anti Clockwise Direction of Retainer Ring-Anti Clockwise Stock Removal Rate(SRR) in microns/min With external drive

1. Weight=150 g/pc Total Wt.=2220 g SRR in microns/min

No. RPM SRR

1 15 5.033

2 30 5.407

3 45 6.47

4 60 8.57

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Graph: 1 SRR Vs RPM

2. Weight=225 gm/pc Total Wt.=3300 gm SRR in microns/min

No. RPM SRR

1 15 3.861

2 30 5.912

3 45 8.89

4 60 10.512

Table: 2 SRR Vs RPM

Graph :2 SRR Vs RPM 5.033 5.407

6.47

8.57

0 1 2 3 4 5 6 7 8 9

0 20 40 60 80

S

RR

RPM

SRR

3.861

5.912 8.89

10.512

0 2 4 6 8 10 12

0 20 40 60 80

SR

R

RPM

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No RPM SRR 1 15 4.943

2 30 7.837

3 45 11.793

4 60 12.943

Table: 3 SRR Vs RPM

Graph: 3 SRR Vs RPM

[image:4.612.169.442.70.395.2]

Table :4SRR Vs RPM

4.943

7.837

11.793

12.943

0 2 4 6 8 10 12 14

0 20 40 60 80

S

RR

RPM

SRR

No RPM SRR 1 15 6.431

2 30 9.785

3 45 10.357

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Graph: 4SRR Vs RPM

TESTING for SRR

Specimen: Ceramic

Hardness: 6 mho Composition: White Alumina (95 %)

Internal Diameter: 13 mm Outer Diameters: 22 mm

Area: 2.474 mm2 Time: 15 min

Abrassive Flow Rate: 10 ml/sec Abrassive: Aluminium Oxide 15 micron

Direction of Lap Plate: Anti Clockwise Direction of Retainer Ring-Clockwise

Stock Removal Rate(SRR) in microns/min With External Drive

No RPM SRR

1 15 4.49

2 30 5.96

3 45 7.891

4 60 9.653

Table: 5 SRR Vs RPM 6.431

9.785 10.357

12.994

0 2 4 6 8 10 12 14

0 20 40 60 80

S

RR

RPM

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Graph: 5SRR Vs RPM

No RPM SRR

1 15 5.021

2 30 5.723

3 45 8.962

4 60 9.963

Table: 6 SRR Vs RPM

Graph: 6SRR Vs RPM 4.49

5.963

7.891

9.653

0 2 4 6 8 10 12

0 20 40 60 80

S

RR

RPM

SRR

5.021 5.723

8.962

9.963

0 2 4 6 8 10 12

0 20 40 60 80

S

RR

RPM

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No RPM SRR

1 15 5.668

2 30 8.153

3 45 9.864

4 60 12.458

Table: 7 SRR Vs RPM

Graph: 7SRR Vs RPM

No RPM SRR

1 15 6.984

2 30 9.548

3 45 12.86

4 60 15.756

Table: 8SRR Vs RPM 5.668

8.153

9.864

12.458

0 2 4 6 8 10 12 14

0 20 40 60 80

S

RR

RPM

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Graph: 8SRR Vs RPM

Testing Results:- SRR

Retainer Ring-Anti-Clockwise

1.ACKW

RPM 2200 gm 3300 gm 4000gm 5000gm

15 5.033 3.861 4.943 6.431

30 5.407 5.912 7.837 9.785

45 6.47 8.89 11.793 10.357

60 8.57 10.512 12.943 12.994

Table: 9 SRR Vs RPM 6.984

9.548

12.86

15.756

0 2 4 6 8 10 12 14 16 18

0 20 40 60 80

S

RR

RPM

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Graph: 9 SRR Vs RPM Compare ACKW

Retainer Ring-Clockwise

2.CKW

RPM 2200 gm 3300 gm 4000 gm 5000 gm

15 4.49 5.021 5.668 6.984

30 5.407 5.921 7.837 9.785

45 6.47 8.89 9.864 12.86

60 9.653 9.963 12.458 15.756

Table: 10 SRR Vs RPM

Graph: 10 SRR Vs RPM Compare 0

2 4 6 8 10 12 14

0 20 40 60 80

S

RR

RPM

2200 Gms

3300 Gms

4000 Gms

5000 Gms

0 2 4 6 8 10 12 14 16 18

0 20 40 60 80

2200 gm

3300 gm

4000 gm

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Testing Result:-

Retainer Ring=Anti Clockwise

1.ACKW

RPM

2200 gm

3300

gm 4000 gm 5000 gm

15 0.4 0.5 0.5 0.5

30 0.4 0.4 0.3 0.5

45 0.5 0.6 0.4 0.5

60 0.3 0.4 0.5 0.4

Table:11 Surface Flatness Vs RPM

Graph: 11 Surface Flatness Vs RPM Compare

Retainer Ring=Clockwise

2.CKW

RPM 2200 gm 3300 gm 4000 gm 5000 gm

15 0.4 0.5 0.5 0.5

30 0.3 0.4 0.4 0.4

45 0.6 0.5 0.5 0.4

60 0.4 0.6 0.5 0.5

Table: 12 Surface flatness Vs RPM 0

0.1 0.2 0.3 0.4 0.5 0.6 0.7

0 20 40 60 80

S

u

rf

ac

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latness

RPM

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Graph: 12 Surface flatness Vs RPM Compare

Testing Results:- Surface Finish Ra

Retainer Ring=Anti Clockwise

1.ACKW

RPM 2200 gm 3300 gm 4000 gm 5000 gm

15 0.493 0.438 0.392 0.527

30 0.404 0.489 0.398 0.489

45 0.502 0.671 0.482 0.502

60 0.397 0.478 0.42 0.489

Table: 13 Ra Vs RPM 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

0 20 40 60 80

S u rf ac e F latness RPM 2200 gm 3300 gm 4000 gm 5000 gm 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

0 20 40 60 80

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Retainer Ring=Anti-Clockwise

2.CKW

RPM 2200 gm 3300 gm 4000 gm 5000 gm

15 0.465 0.593 0.482 0.398

30 0.398 0.485 0.494 0.472

45 0.634 0.57 0.373 0.495

60 0.456 0.629 0.572 0.438

Table: 14Ra Vs RPM

Graph: 14Ra Vs RPMCompare

CONCLUSIONS

1. Higher SRR is achieved by applying external drive.

2. The relationship between SRR and RPM of retainer ringis established.

3. With the various combinations of rotational direction of retainer ring, dead weights and RPM of Lap plate and retainer ring the stock removal rate varies in range of 4 microns /sec to 15.5 microns/sec.

ACKNOWLEDGEMENT

This work was guided by and completed at SpeedFam India Pvt. Ltd., Ambarnath.

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

0 20 40 60 80

S

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RPM

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REFERENCES

1. Patil, Mayur P. "Study Of Stock Removal Rate Of White Ceramic In Single Side Lapping Process." International Journal of Mechanical and Production Engineering Research and DevelopmentOCT 2016 6.5 (2016): 1-10. Web. 31 Oct. 2016.

2. "Lapping Machines, Lapping, Polishing Machines, Polishing, Lapping and Polishing Consumables, Polishing Machine Manufacturers, Polishing Machine Suppliers from India."Lapping Machines, Lapping, Polishing Machines, Polishing, Lapping and

Polishing Consumables, Polishing Machine Manufacturers, Polishing Machine Suppliers from India. N.p., n.d. Web. 20 Aug. 2015.