An experimental study has been made of the superfinishing process. A force measurement system, developed for external cylindrical superfinishing, has been used to directly measure the forces acting on the abrasive stone. A systematic parametric study of material removal rate, force ratio, specific energy and surface finish is detailed. The force ratio and specific energy are found to be sensitive indicators of the cutting action of the stone. This indicates that the force ratio could be used to monitor the process, online in industrial applications. The two regimes of rough finishing and fine finishing have been characterized. A sharp transition from fine to rough finishing occurs at a stone oscillation frequency of about 1600 cpm. This characteristic frequency is mostly independent of stone-work contact pressure. The experimental data is used to construct a superfinishing process map, analogous to the wear-regime map, to depict the various regimes in which different modes of superfinishing dominate.

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