Research Papers

Research on Ultrasonic-Assisted Fixed-Abrasive Lapping Technology for Engineering Ceramics Cylindrical Part

[+] Author and Article Information
Feng Jiao

School of Mechanical and Power Engineering,
Henan Polytechnic University,
2001 New Century Road,
Jiaozuo 454003, Henan, China
e-mail: jiaofeng@hpu.edu.cn

Bo Zhao

School of Mechanical and Power Engineering,
Henan Polytechnic University,
2001 New Century Road,
Jiaozuo 454003, Henan, China
e-mail: zhaob@hpu.edu.cn

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received November 16, 2016; final manuscript received November 29, 2016; published online January 10, 2017. Editor: Jian Cao.

J. Micro Nano-Manuf 5(2), 021001 (Jan 10, 2017) (7 pages) Paper No: JMNM-16-1065; doi: 10.1115/1.4035391 History: Received November 16, 2016; Revised November 29, 2016

Lapping is a key processing step for precision parts, which directly affects machining quality, precision, and efficiency. Due to some drawbacks of free-abrasive lapping such as deep scratches on the lapped surface, lower lapping efficiency for lower lapping speed, severe waste of abrasive, high-processing cost, and so on, conventional fixed-abrasive lapping (CFL) technology was proposed and developed recently. Meanwhile, considering the unique advantages of the ultrasonic-assisted machining during the processing of those hard and brittle materials and the effect of ultrasonic vibration on the self-sharpening characteristic of abrasive pellet, a novel ultrasonic-assisted fixed-abrasive lapping (UAFL) technology is put forward and corresponding lapping device for engineering ceramics cylindrical part is developed in this paper. Meanwhile, UAFL mechanism and characteristics were studied theoretically and experimentally. Research results show that superimposed ultrasonic vibration changes the lapping movement characteristics and material removal mechanism to a certain extent, helping to heighten material removal rate, smoothen the waveform of tangential force, reduce the average tangential force, and improve surface machining quality. UAFL can be regarded as a high efficiency and precision processing technology for engineering ceramics cylindrical part.

Copyright © 2017 by ASME
Topics: Grinding , Ceramics
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Fig. 1

Sketch map of cylindrical part lapping

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Fig. 2

Two lapping models: (a) free-abrasive lapping and (b) fixed-abrasive lapping

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Fig. 3

Ultrasonic-assisted fixed-abrasive lapping device

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Fig. 4

A series of lapping tools

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Fig. 5

Lapping pressure adjustment system

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Fig. 6

Resultant speed in ultrasonic-assisted lapping

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Fig. 7

Change rule of rake angle for the assistance of ultrasonic vibration

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Fig. 8

Blank cutting phenomenon of grain with axial ultrasonic vibration

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Fig. 9

Calibration of dynamometer: (a) diagrammatic sketch of calibration and (b) result of calibration in Z direction

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Fig. 10

Lapping force waveforms (lapping condition: P = 100 N, n = 250 rpm, f = 0.128 mm/r, and grit size 28 μm): (a) lapping without ultrasonic assistance and (b) lapping with ultrasonic assistance

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Fig. 11

Material removal rate (MRR) characteristic: (a) effect of lapping speed on MRR and (b) effect of lapping pressure on MRR

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Fig. 12

Surface roughness characteristic: (a) effect of lapping speed on Ra and (b) effect of lapping pressure on Ra

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Fig. 13

SEM photos of lapped surface of ZrO2 ceramic: (a) with ultrasonic assistance and (b) without ultrasonic assistance



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