2023

AUTOMOBILE ENGINNERING
GROUP- 1
MICROPROJECT REPORT
SUBJECT- AUTOMOBILE
MANUFACTURING PROCESS
 Micro Project Report
Plan A
AMP
Automobile Manufacturing Process

Department-Automobile Engineering
Fourth Semester

Topic- Surface Finishing Process Used in Manufacturing

Group Member
Roll No Name Enrollment No
2601 Prathamesh Mahesh
Gothankar
2604 Vivek Walzade
2605 Sasmit Mohite
Sahil Khan

Brief description
VARIOUS MANUFACTURING PROCESS
Surface finishing process used in manufacturing
1)lapping
In automotive or industrial settings, lapping can refer to a
machining process that involves rubbing two surfaces together
with an abrasive material to create a very smooth and precise
fit.
2)Horning
Honing is an abrasive machining process that produces a
precision surface on a metal workpiece by scrubbing an
abrasive grinding stone or grinding wheel against it along a
controlled path. Honing is primarily used to improve the
geometric form of a surface, but can also improve the surface
finish.

3)Buffing polish
The buffing process involves rubbing the surface with the
abrasive material, which helps to remove any remaining
imperfections or roughness in the surface. The process is often
used on metals, such as stainless steel, aluminium, and brass,
to achieve a mirror-like finish.

ACTION PLAN
Serial no Details of Plan start Plan finish Name of
activities date date responsible
team
member
1 Group Prathamesh
formed gothankar
selection of
microproject
2 Discussion Prathamesh
about topic gothankar
dividing
work
equally
among the
member
3 Searching Prathamesh
the given gothankar
topic
collecting
information
4 Checking Prathamesh
the collected gothankar
information
with
respected
teachers
5 Start making Prathamesh
of gothankar
microproject
6 Clearing Prathamesh
small doubts gothankar
with
respected
teachers
7 Presenting Prathamesh
and gothankar
checking our
 project by
the
respected
teacher
8 Submission Prathamesh
of micro gothankar
project with
report

RESOURCES USED
1. Microsoft word 2021
2. Google chrome
3. Web images
4. Wikipedia

SIGNATURE OF TEACHER

PLAN B
Aim of microproject
Collect information about surface finish process
1)Buffering polish
2)Honing
3)Lapping
Course outcome
Collecting information about finishing process and their
application in real world
ACTUALL METHODOLODGY FOLLOWED
1)Lapping process
Lapping is a low-pressure machining process used to increase
the dimensional accuracy and surface finish of the workpiece.
The lapping process uses fine abrasive particles to perform
cutting action on the surface of the workpiece. The workpiece is
rubbed against the lapping plate with the help of a machine or by
hand, with powdered abrasive particles or abrasive paste in
between. The lapping process smoothens outs the surface of the
workpiece, this increases the functionality and aesthetics of the
workpiece. It is also used to ensure the correct fit between two
workpieces and correct minor imperfections.
Principle Of Lapping Process
The simple working of a lapping process involves three
elements. A workpiece, a lapping plate, and Abrasive particles.
Abrasive particles are poured over the lapping plate and the
workpiece is rubbed on it. The Abrasive particles remove
microscopic material from the workpiece when a force is applied
during the relative motion between the plate and the workpiece.
The Abrasive particles tend to reduce or flatten the microscopic
peaks and valleys present on the surface of the workpiece.

Characteristics Of the Lapping Process

 The size of Abrasive grit used in the lapping process varies
from 120 to 1200 mesh depending upon desired surface
smoothness.
 The abrasive used can be in powdered form or can be mixed
with some suitable oils or greases called vehicles.
 A very small amount of material is removed in the lapping
process that is about 0.025mm.
 The lapping process can be done manually or with the help of
machines.
 Materials commonly lapped are hard materials like steel.
 The pressure applied during the lapping process is low when
compared to other surface finish processes.
MACHINE USED FOR LAPPING PROCESS
1) Vertical lapping machine
2) centreless lapping machine
3) Spherical lapping machine
4) belt lapping machine
Lapping Process Parameters
 Lapping speed: The lapping speed for an ideal lapping
operation must range from 1.5 to 4m/s
 Lapping pressure: Lapping pressure depends upon the
hardness of the material and the Abrasive particles used.
Lapping pressure varies from 10 to 30kPa for soft materials
and up to 70kPa for hard materials.
 Lapping allowance: Lapping allowance is directly
proportional to the lapping time. As the lapping allowance
increases, lapping time also increases. The lapping allowance
also depends on the material being lapped.
 Cast iron – 0.2mm
 Aluminium alloy – 0.1mm
 Soft steel – 0.05 to 0.1mm
 Hardened steel – 0.005 to 0.02mm
APPLICATIONS OF THE LAPPING PROCESS
The lapping Process is used for polishing hard and brittle
metals which are difficult to be polished using other methods.
 It is also used for machining materials like glass due to its
slow material removal rates.
The lapping process is widely used for making specimens for
metallurgical testing.
The lapping process is used for valve manufacturing due to its
accurate uniform material removal feature.
Automotive industries also use lapping processes for various
polishing operations.

Lapping machine

2)Honing process
Honing is an abrasive machining process that is a combination
of grinding and drilling processes. A honing process uses an
Abrasive grinding tool to accurately machine the given
 workpiece. A honing process improves the surface quality of
the workpiece as well as provides dimensional accuracy to the
part being machined.
A moving Abrasive stone is made to come in contact with the
part to be machined hence producing an accurate finished job.
Honing is used in industries where accuracy and aesthetics
both are considered important. Generally, a honing process
uses CNC to direct the tool on the workpiece. A honing
process is mostly used to finish the boreholes in a workpiece.

3)Characteristics of Honing Process

The following are the characteristics of Honing Process
 It is a low-velocity, highly accurate process.
 The honing process generates a cross-marked surface on the
workpiece. This workpiece is used to hold lubricants.
 It can be used for correcting the roundness of the hole.
 High tolerance of 2 to 3 microns can be achieved.
 Both hard and soft materials can be honed.
 The range of cutting speed varies from 0.25 to 1m/s.
 The cutting angle ranges from 60 to 90o.
 The pressure applied on the lateral surface area of the
workpiece during the honing process ranges from 1000kPa to
2500kPa.
Working Principle of Honing Process
The basic principle involved in the honing process is the
cutting action performed by the Abrasive particles when a
linear, as well as a tangential force, is applied. The friction
 generated by the contact of Abrasive stones and the workpiece
results in the material removal from the workpiece.

Honing Machine Types

There are two types of honing machines which are as follows
 Vertical Honing machine
 Horizontal Honing machine

Vertical honing machine

 Horizontal honing machine

Applications Of Honing Process

 It can be used for finishing automobile crankshafts
 Honing process is used for finishing gears in the automobile
industry.
 It is also used for production purposes where hollow
cylindrical bores must be accurately finished.
 It is also used for finishing the internal diameter of the IC
engines.
 It can be used for improving hole roundness.
 Honing machine

3)Buffing
Both Buffing and Polishing Process is a common term and
these are used in Manufacturing Processes or you can say
manufacturing industry. Both processes are finishing or
superfinishing processes used for enhancing the surface of the
workpiece in both ways (Physical and Aesthetic Properties).
The buffing process is used to shine wood, metal, or
composites using a cloth wheel impregnated with cutting
compounds or rouges. In the cloth, there is an abrasive disc
that works is to remove or cut and get a better surface finish.
This process is performed after polishing process for
providing a high luster to be polished surface.
Buffing Process:
The buffing wheel is made by linen, cotton, broad cloth and
canvass and it is made by multiple layers of these cloths
overlapped on each other.
When we perform an operation, The wheel is attached with the
tool holder and when operation starts it rotates during at a speed
of 32.5 -40 m/s and a small pressure applied on the wheel which
promotes abrasive action and removes metal in form of
microchips.
It is used to remove fine scratches or to remove oxide or similar
coatings which may be on the work surface.
Application of Buffing Process:
The following application of Buffing Process is:
 The buffing process is used to remove scratches, oxides,
coatings from the workpiece surfaces.
 Used in the automobile sector, motorcycles, boats, bicycles,
commercial and residential hardware, and much more.
 Also used in the automotive sector (Component is Roller
bearing, connecting rod, piston, and many more).
 The process used to shine the workpiece. It may be Tools,
fixtures, or sports items.
 The buffing process also used in Household utensils and
appliances.

Buffing polishing process

Conclusion
All this process is required for final finishing and making
product with accurate dimensions.
A proper finish can be obtained by selecting the type of metal
and considering time requires for working.