Abstract
The lapping process is strongly affected by a number of input parameters. One of the fundamental mechanical processes in lapping is the abrasive effect of particles. In order to examine the influence of the kinematic parameters on the lapping uniformity of unconventional single-sided machine, numerical simulations of particles sliding trajectories are performed. Changing the kinematic parameters, e.g., rotational velocities or position of the conditioning rings together with the workpieces can be used for correcting the profile of an active surface of the lap. This paper provides a basic guide to the kinematic parameter settings of single-sided lapping process. Furthermore, an unconventional single-sided lapping system, where a conditioning ring performs additional motion during the machining, is described. Simulation results show that the rotational speed ratio of the conditioning ring to the lapping plate k1 and the period ratio of the reciprocating motion to the lapping plate rotary motion k2 represent the relationships among the three basic motions of unconventional lapping systems and are major factors affecting trajectory distribution. Material removal rate and trajectory density parameter are proposed to optimize the kinematic parameters for better uniformity of lapping plate wear. The preferred kinematic parameter values for single-sided lapping system with reciprocating motions and the assumed size of the machine are k1 = 0, 78 and k2 = 2. The general results were validated on a specially designed test stand.
Highlights
In order to achieve high-quality surfaces with low roughness, very high accuracy of shape and dimensions, finishing technologies become more important and are nowadays state of the art
This paper provides a basic guide to the kinematic parameter settings of the single-sided lapping process
Numerical simulations of particle sliding trajectories and their uniformity based on kinematic analysis are presented, in order to determine the optimal kinematic parameters
Summary
In order to achieve high-quality surfaces with low roughness, very high accuracy of shape and dimensions, finishing technologies become more important and are nowadays state of the art. The single-sided lapping process is affected by numerous technologically based conditions, which have an influence on the tool wear, workpiece quality, and efficiency of the process. It can be stated that during a single-sided lapping process, a tool, type of abrasives and workpieces, kinematics, and machine parameters decisively affect the mechanism of surface formation [8]. Previous researches on single-sided lapping kinematics have focused primarily on determining an influence of workpieces geometry, their distribution in conditioning rings [11], and analysis of abrasives path distribution [15]. An experimental stand has been described and a set of tests for different parameters were conducted
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