LAPPING
LAPPING
Precision finishing operation
Carried out using fine abrasive
materials
PURPOSE
Improves geometrical accuracy
Refines surface finish
High degree of dimensional accuracy
Improves quality of fit b/w mating parts
LAPPING PROCESS
Small amounts of material are
removed by
Rubbing the work against a lap
charged with a lapping compound
LAPPING PROCESS
Lapping compound consists of fine
abrasive particles suspended in a
'vehicle'
Example: oil, paraffin, grease etc.,
LAPPING PROCESS
lapping compound introduced
between the workpiece & the lap
Chips away the material from the
workpiece
LAPPING PROCESS
Light pressure is applied when both
are moved against each other
Lapping can be carried out
manually or by machine
HAND LAPPING OF FLAT SURFACES
Flat surfaces are hand-tapped using lapping plates made
out of close grained cast iron
HAND LAPPING OF FLAT SURFACES
Surface of the plate should be in a true plane for accurate
results in lapping
HAND LAPPING OF FLAT SURFACES
Work piece is rubbed against the plate in a figure eight
pattern
HAND LAPPING OF FLAT SURFACES
Lapping plate used in tool rooms
will have narrow grooves cut on its
surface both length-wise & cross-
wise forming a series of squares
HAND LAPPING OF FLAT SURFACES
Grooves are usually about 12 mm apart
While lapping, the lapping compound
collects in the serrations & rolls in and
out as the work is moved
HAND LAPPING OF FLAT SURFACES
Before commencing lapping of the
component, the cast iron plate
should be charged with abrasive
particles
LAPPING
Lapping is intended as final finishing
operation
An impractical or uneconomical means
of removing stock
LAPPING
Less than 0.13mm material is removed
in lapping
Flatness is the most common goal of
lapping
LAPPING
Low speed
Low pressure
Dimensional accuracy (flat / spherical)
Close parallelism
Refinement of surface finish
Close fit between mating parts
OPERATION
Hand lapping plate of CI (cast iron) is used
OPERATION
Emery powder, Silicon carbide,
aluminium oxide, diamond, etc is
used as lapping compound to lap
steel work piece
LAPPING EXTERNAL AND INTERNAL CYLINDRICAL SURFACES
OPERATION
In manufacturing processes, a high degree
of accuracy is required in jigs and fixtures
Therefore lapping becomes necessary for
finishing holes, which are hardened.
LAPPING INTERNAL CYLINDRICAL SURFACES
Solid or adjustable types of laps are used for
lapping internal cylindrical surfaces/ holes
LAPPING EXTERNAL CYLINDRICAL SURFACES
Adjustable ring laps of various designs are
available for lapping external cylindrical surfaces
LAPPING EXTERNAL CYLINDRICAL SURFACES
The simplest form is a split bush with clamping
screws, which permits some adjustment of sizes
LAPPING EXTERNAL CYLINDRICAL SURFACES
Ring lapping can be done manually or by
holding the work on the lathe while the split
ring is moved over the cylindrical surface
LAPPING EXTERNAL CYLINDRICAL SURFACES
While lapping, the ring lap should slide forward
& backward along the workpiece - rotating the
lap at the same time in alternate directions
TYPES OF LAPPING
Wet lapping
Dry lapping
WET LAPPING
In wet lapping there is surplus oil &
abrasives on the surface of the lap.
As the workpiece, which is being lapped,
is moved on the lap, there is movement of
the abrasive particles also.
DRY LAPPING
In the dry method the lap is first charged
by rubbing the abrasives on the surface
of the lap.
The surplus oil and abrasives are then
washed off.
DRY LAPPING
The abrasives embedded on the surface of
the lap will only be remaining.
The embedded abrasives act like a fine
oilstone when metal pins to be lapped are
moved over the surface with light pressure
DRY LAPPING
However, while lapping, the surface being
lapped is kept moistened with kerosene or
petrol.
Surfaces finished by the dry method will
have better finish and appearance.
Some prefer to do rough lapping by wet
method and finish by dry lapping.
LAPPING ABRASIVES
Commonly used abrasives are:
Silicon carbide
Aluminum oxide
Boron carbide
Diamond
Silicon carbide
This is an extremely hard abrasive. Its grit is sharp
and brittle.
While lapping, the sharp cutting edges continuously
break down exposing new cutting edges.
Due to this reason this is considered as very ideal for
lapping hardened steel & cast iron, particularly where
heavy stock removal is required.
Aluminium oxide
Aluminum oxide is sharp but tougher
than silicon carbide.
Aluminum oxide removes stock
effectively & is capable of obtaining
high quality finish.
Diamond
This being the hardest of all materials, it
is used for lapping tungsten carbide.
Rotary diamond laps are also prepared
for accurately finishing very small holes
which cannot be ground.
Boron carbide
This is an expensive abrasive material which
is next to diamond in hardness.
While it has excellent cutting properties, it is
used because of the high cost only in
specialized application like dies and gauges.
LUBRICANTS
Commonly used lubricants are:
Water soluble cutting oils
Vegetable oils
Machine oils
Petroleum jelly or grease
Lubricants with oil or grease base used for lapping ferrous
metals.
Metals like copper & its alloys and other non-ferrous metals
are lapped using soluble oil, bentomite, etc.
PRECAUTIONS TO BE OBSERVED WHILE LAPPING
Do not dwell in the same place while lapping
Keep the lap moist always
Do not add fresh abrasive during lapping;
recharge if necessary.
Do not apply excessive pressure while
lapping
SURFACE MEASUREMENT
Surface roughness & surface flatness are
different .(often confused)
Roughness - profilometer in microns.
Flatness in HLB(Helium Light Bands).
One HLB = 280 nm.
MACHINES
MACHINES
DOUBLE SIDE LAPPING MACHINE
ADVANTAGES
Simplest operation.
No much cost when compared to other
operations.
Improves geometrical accuracy.
Achieves high dimensional accuracy.
It ensures close fit between mating parts.
DIS-ADVANTAGES
Time consuming process
Skilled workers is required
Less amount is very low
LAPPING