Types of Metal Polishing Techniques and Their Polished Step

Metal polishing offers various benefits during metal fabrication, including highlighted shapes, designs, and features. This section will discuss some of the common benefits of metal plate polishing.

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1. Product Aesthetics

Generally, machined metal parts don’t automatically get the smooth and appealing surface you commonly see on them. The abrasive wheels of the polishing machine smoothen the machined components’ rough surfaces. It removes the scratches, imperfections, tarnishes, and nicks on the machined component’s surface, ensuring a smooth and glossy surface.

However, the desired specifications for product aesthetics may determine the processing time and cost of metal parts.

2. Provides a Protective Layer

Metal polishing, like titanium polishing, offers more significant benefits beyond improving the surface quality of your metal products. Polished metals perform better and appear good longer than unpolished metals.

Polishing’s abrasive process helps to resist contamination and oxidation on metal surface finish. It provides a protective layer of metal, usually a reflective surface capable of reducing wear and tear or corrosion.

3. Improved Light Reflection

The surface of polished metal parts shines brighter and more vibrant resulting in effective light reflection. Hence, this property is beneficial in applications requiring highly reflective properties, including architectural elements, jewelry, and decorative items.

4. Better Functionality

Metal polishing improves metal components’ functionality in specific applications such as precision instruments and machinery components. Polishing eliminates all surface imperfections, achieving a smooth and even finish. Additionally, metal surface polishing reduces friction, improving overall performance and conductivity.

5. Increased Cleanliness

The metal polishing techniques give your parts the appropriate finish, preventing the risk of bacteria and germs, which could damage and worsen the surface. In addition, you can easily clean and maintain properly polished metal components due to their smooth surfaces. It allows efficiency by reducing the required cleaning time for the material.

Furthermore, there is a reduction in the amount of harmful chemicals used in cleaning the metal surface. Meanwhile, some chemicals increase the rate at which the surface of metal parts wears and corrode.

Product engineers commonly utilize various polishing techniques to enhance the surface quality of their metal products. Before discussing the different techniques for metal polishing, let’s check the pre-polishing procedure you should know.

Surface Preparation Before Polishing

Preparing the metal surface to be polished properly before polishing is crucial. Here are some steps to follow for better surface preparation:

• Remove Rust or Corrosion: You must remove any rust or corrosion on the surface of a metal part before polishing.
• Clean the Surface: Eliminate any grease, debris, or contaminant from the metal’s surface using a suitable cleaning agent such as a mild detergent.
• Smooth-Out Imperfections: Smoothen all dents, scratches, and imperfections on the metal’s surface.
• Rinse and Dry: You have to rinse off any cleaning agent, abrasives, or rust removal residue after eliminating all imperfections from the metal’s surface. Wipe off and dry the surface thoroughly to avoid water spots and corrosion.

After being ready for the metal surface, this section explores the step-wise guide to metal polishing techniques.

1. Hand Polishing Technique

Hand polishing is a manual technique involving different polishing compounds and tools. It requires direct contact between the metal surface and the polisher. Although hand polishing consumes more time than machine polishing techniques, it provides personalized, controlled, and precise results. Below are the steps involved in the hand-polishing process:

Select and Apply the Polishing Compound

Choose a suitable polishing compound depending on the type of metal and preferred finish. Typical examples of polishing compounds include jeweler’s rouge, metal polishes, and rubbing compounds.

Start Polishing

Rub the metal surface with a polishing compound in a circular or back-and-forth motion using moderate pressure. Polish continuously until you achieve the preferred level of shine. However, you may need to re-apply the compound as necessary.

Clean and Inspect

Clean the metal’s surface with a soft cloth to wipe off residues of the polishing compound once you have achieved the desired polishing. Also, inspect the part’s surface for any imperfections or areas needing further processing.

2. Machine Polishing Technique

Machine polishing technique uses power tools such as dual-action or rotary polishers. Metal types compatible with this technique include titanium, nickel, chrome, bronze, stainless steel, and copper.

Manufacturers in various industries such as electronics, aerospace, and medical devices usually use machine polishing techniques for desired results.

Below is a step-wise guide for machine polishing technique:

Choose the Right Polishing Pad

Use the appropriate polishing pad depending on the required polishing level. The various polishing pads suitable for machining polishing include wool, foam, or microfiber pads with varying levels of aggressiveness.

Apply the Polishing Compound

Apply a small amount of polishing compound onto the polishing pad. Ensure you coat the pad evenly but don’t overload the metal surface with compound.

Program the Speed and Begin Polishing

Program the machine polisher to the preferred speed. Then, begin polishing by operating the machine in a slow, overlapping motion across the surface of the machined parts. Apply moderate pressure while polishing and avoid polishing one spot for longer to prevent heat buildup.

Check the Progress

Stop and inspect the metal polishing’s progress periodically. Wipe-off excess polishing compound and check the surface for any defects. Replace the polishing pad if required and regulate the polishing pressure and speed.

Complete the Polishing

Use a soft cloth to clean the metal’s surface to eliminate any residue once you have achieved the preferred level of shine.

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3. Chemical Polishing Technique

This technique involves using specialized chemical compounds to eliminate thin layers of the metal’s surface, providing an improved and aesthetically appealing exterior. The chemical polishing process is an ideal technique for delicate parts. Here is a breakdown of the chemical polishing technique:

Select a Suitable Chemical Polishing Solution

There are varying chemical solutions available for this technique, depending on the type of metals. Etchants are a primary element in these solutions. It selectively dissolves the surface layer of the metal sheet.

Prepare the Solution

Mix the chemical polishing solution correctly by following the provided instructions. Usually, the mixtures involve diluting the compound with a certain solvent or water.

Submerge the Metal Object

Bathe the metal component in the chemical polishing compound. Ensure the metal component is fully submerged and the solution spreads across the metal surface marked for polishing.

Monitor the Chemical Process

You must be very careful with the chemical polishing of metal components because it is a delicate process. Monitor the reaction of the metal parts with the polishing solution. However, the required time for polishing depends on the metal type and the required outcome.

Rinse and Dry

Rinse the metal parts thoroughly with water after removing them from the solution. Then, dry the moist completely to avoid any water spots or corrosion.

There are different types of polishing finishes suitable for your metal products. Let’s check the details.

1. Mirror Finish

Mirror or high-polish finish type offers high reflectivity, which is best for stainless steel products. It is an excellent finish for concealing welded metal components, allowing easy cleaning. The process requires careful polishing and buffing techniques. The mirror metal polishing finish gives the final product a reflective surface, almost like a mirror, usually smooth and flawless.

2. Brushed Finish

This metal polishing finish produces an aesthetic pattern comprising delicate parallel lines. It is the perfect finish for parts intended for outdoor or indoor applications where they are exposed to sunshine or bright indoor light. Most kitchen appliances often bear a brushed finish. However, you must use a high-grade abrasive to ensure the lines are uniform.

3. Satin Finish

The satin finish is a standard metal polishing type that offers a toned-down, low-gloss appearance. You can use fine abrasives to polish your metal parts to achieve an even surface with a slight appearance.

This polishing finish result gives the metal a smooth touch and more subtle elegance. The satin finish is suitable for applications requiring a refined appearance, such as jewelry, household appliances, and architectural elements.

4. Antique Finish

Antique polishing finish enhances the appearance of aged or eroded metal with an antique look. This polishing type is applicable to furniture, architectural elements, and decorative items, building a sense of history and character.

You can combine processes such as manual distressing techniques, patination, and chemical treatments to achieve an antique or vintage finish. Depending on the preferred aesthetic, These methods form various effects, including discoloration, tarnishing, or a worn-out appearance. However, the primary purpose is to imitate the natural aging process and equip the metal with a lasting, antique appeal.

CNC machining copper is one of the most efficient processes for manufacturing copper parts for various industries. Copper has high corrosion resistance, electrical conductivity, thermal conductivity, strength, and ductility, so industries such as automotive, aerospace, and medical require a large number of CNC copper parts. In terms of CNC processing, pure copper has poor machinability due to its high plasticity and toughness. Alloying elements such as zinc, tin, aluminum, silicon and nickel with copper can change the composition of the material and can greatly improve machinability. CNC machining copper operations include: milling, turning, slotting, drilling, tapping, counterboring, chamfering, threading, knurling, brazing, grooving, trimming, and nickel plating.

Copper is an extremely versatile metal, making it one of the best options for CNC machining custom parts. Copper has several useful properties.

Extremely good electrical and thermal conductivity – Copper is almost as good as silver and better than gold. Copper is widely used in the electrical and electronics industries. The average car has been calculated to contain more than 22 kilograms (approximately 48 pounds) of pure copper.

Corrosion Resistance – Copper can be applied where it will be exposed to corrosive agents such as salt water. One of the reasons why this material is used on the exterior of the Statue of Liberty in New York, for example. It is worth mentioning that it also has the function of anti-ultraviolet radiation.

Bactericidal, viral and fungicidal properties – it makes copper a perfect material for the production of antimicrobial doorknobs and doorknobs (especially in public places, clinics and hospitals), sometimes used in specialized wound dressings (along with silver) and in agriculture (For example, for some types of crops, “copper spray” is used due to its fungicidal properties).

Copper is easily recycled – it is estimated that more than 80% of the copper mined to date is in continuous use. Even after repeated processing, the material does not lose its properties.

Since copper is very soft, this often results in tool wear and poor chipping during CNC machining. In CNC machining, built-up edge occurs when a portion of the copper workpiece breaks off and is bonded to the cutting tool, resulting in poor surface finish on the machined copper part.

AN-Prototype recommends that you use cutting tools made of high-speed steel (HSS) for CNC machining copper, as they are known to ease these barriers. Additionally, cutting tools must be ground to a good cutting edge before CNC machining copper.

Feed rate describes the rate at which the CNC cutting tool feeds (or advances) relative to the workpiece. We recommend low to moderate feed rates when CNC machining copper, as high feed rates often result in high temperatures, making copper more difficult to precision machine. A general recommendation is to remove no more than 0.2mm of material per pass. The tool feed rate should be maintained at 4-6 mm/s and the depth of cut should not exceed 30% of the tool diameter.

AN-Prototype provides a complete CNC machining copper service, fully capable of manufacturing complex copper parts in C110 and C101. Copper parts are corrosion resistant and versatile, and can be used in applications that require electrical conductivity and higher quality aesthetics. We operate 3-, 4-, and 5-axis CNC mills and turning centers, and are able to machine anything you need, from simple “as-machined” workholding to complex organic geometries with tight tolerances. AN-Prototype can provide up to 7 different post treatment/surface treatment options including sandblasting, powder coating, smooth finishing and polishing.

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