Semibonded Abrasive Grinding Plate And Its "Trap" Effect Simulation And Experimental Verification

Efficiency, high-precision and low-surface damage are always the target of ultra-precision machining which is pursuing for. With the development of modern industry, the requirements of ultra-precision processing technology become higher and higher, in the processing, the contradictions between lowing surface damage and increasing the efficiency of processing become prominent. To ease this problem, our research centre puts forward the semi-solid abrasive lapping tool processing technology that integrates with solid abrasive machining and free abrasive machining technology. The core of the semi-solid abrasive lapping tool is using "trap" effect for ultra-precision machining. The abrasive tool can effectively prevent the surface damaging caused by large particles in the lapping, the tool can also improve processing efficiency and accuracy.The article refers to the conventional abrasive tool's manufacturing processes, according to characteristics of the semibonded abrasive lapping plate, we improve the semibonded abrasive lapping plate's manufacturing process, and also propose the perfect processing process .With the study of combination and Additives, the suitable formula for a semibonded abrasive lapping plate is determined.According the parameters of traditional abrasive lapping tool detection methods, chose hardness, shear strength, compression , rebound rate and abrasives organizations of the key parameters of abrasive tool as semibonded abrasive lapping plate's evaluation parameters, and construct evaluation system of the semibonded abrasive lapping plate. Based on the characteristic parameters of the semi-solid abrasive lapping tool, we establish PFC model of the semibonded abrasive lapping plate, and select the parallel connection stiffness as adjust parameter. When determining the parameters and scope of choices, we simulate the large particles "trap" effect, then discuss the bonding strength, processing load, such as the diameter of the particles' affect on the "trap" effects.With two aspects of direct and indirect, we verify that "trap" effect of semibonded abrasive lapping plate is existence. Adopting hemispheric pres head to simulate big abrasives, then the plunge experiment of plunge can be carried on. After simulation experiment, large particles can completely press into the semibonded abrasive lapping plate. The necessary plunge load is connected with the hardness of the semibonded abrasive lapping plate. The indirect verification of "trap" effect refers to the different abrasive tool, and we simulate mixing rigid large particles in the lapping process, then compare with surface damage. Either in dry or wet processing conditions, the SSB-2 semi-solid abrasive lapping tool always performs good "trap" effect, the surface damage of the test sample is minimum.In lapping experiments, we use the appropriate parameters to study the semibonded abrasive lapping plate's machining characteristics. The experimental result shows that the remove effect of the semibonded abrasive lapping plate is almost the same with the free abrasive lapping, but the semibonded abrasive lapping plate can obtain lower surface roughness, processing performance can also be greatly improved. With the hardness of the semi-solid abrasive lapping tool increasing, its remove rate can also increased, but the surface roughness will be increased after lapping; with the shear strength of the semi-solid abrasive lapping tool increasing, its wear can be reduced.