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Three stages are involved in polishing, namely, 1. a roughing stage to remove maximum material without imparting any damage to the surface, 2. an intermediate stage of semi-finishing to control the size and improve sphericity, and 3. a final finishing stage to obtain best surface finish and sphericity while maintaining the final diameter.
The best surface finish was found by using a ramp-down waveform with relaxation time.
The best surface finish was obtained when a ramp-down spike in a ramp-down waveform was used.
The best surface finish achieved with optimally blended abrasive medium on Al alloy/SiC (10%) metal matrix composite (MMC) is 110 nm.
The best surface finish of 3.5 nm was obtained using 1 μm abrasive particle size colloidal suspension at 7.5 N load, 2400 rpm spindle speed, 90 shore A tool stiffness and 3 min of polishing time.
The PCD tool gave the lowest force values associated with best surface finish, followed by the ISO grade K15 uncoated carbide tool with chip breaker when machining reinforced polyamide.
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Additionally, results of analyses of means and the validation experiments confirm that the optimum cutting conditions derived by this method produce far better surface finish than the best finish obtained during the course of experimentation.
If power consumption minimization is to be achieved for the best possible surface finish, the most recommended combination of feed rate and depth of cut is also determined.
From SEM micrograph, machined surface indicates feed marks, adhered oxides and chip particles, surface voids, material side flow, un-machined material, smooth and rough surface at the surface obtained best and poor surface finish in hard turning of AISI 4340 steel with coated carbide tool.
The semi-finishing teeth provide surface finish and the finishing teeth provide the final finishing.
For the machine used in this research, the best surface roughness Ra after finishing process is about 0.7 μm.
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