Speed ratio optimization for ceramic lapping with fixed diamond pellets

Abstract

High efficiency and stability are known as the advantages of fixed abrasive lapping for fabricating various materials, which are due to the effective positions of fixed abrasives on the tool surface and controllable trajectories during lapping. For speed ratio is regarded as one of the most important parameters in governing abrasive trajectory distribution, this work will focus on optimizing speed ratio of a fixed abrasive diamond pellet (FADP) pad for lapping alumina ceramic in order to reveal the influence of speed ratio on abrasive trajectory distribution and lapping results, which is of most importance to achieve a better surface workpiece. To obtain an optimal speed ratio in lapping, a method of extracting abrasive position information is put forward, and it is further used to optimize speed ratios based on trajectory analysis. Lapping experiments are carried out on alumina ceramics by a FADP pad, and removal characters of the FADP pad are investigated, including removal profile, surface morphology, trajectory scratches, surface roughness, and etc. Results show that the arranged structure of the FADP pad aggravates the influence of speed ratios on abrasive trajectory distribution. With the optimal speed ratios, better flatness and surface roughness of alumina ceramic can be achieved for the lower trajectory non-uniformity and a more complex trajectory distribution. The method of abrasive position information extraction and trajectory analysis can be used to optimize speed ratio for special lapping pads in different applications, especially for structured pad, which can further take advantage of fixed abrasive pads.