ABSTRACT

Carrier ....................................................................... 156 4.3.4 Lapping by Ultrasonic Vibration............................................ 158

4.3.4.1 Principle of Ultrasonic Exciter................................. 158 4.3.4.2 Application to Lapping of Ultrasonic Vibration ..... 158

4.4 ELID-Lap Grinding ............................................................................ 159

Hitoshi Ohmori

4.4.1 Introduction ............................................................................. 159 4.4.2 Principle of ELID-Lap Grinding ............................................ 160 4.4.3 Experimental Systems............................................................. 162 4.4.4 Experimental Method.............................................................. 163 4.4.5 Characteristics of ELID-Lap Grinding................................... 163

4.4.5.1 Effects of Grain Size on Surface Roughness and Removal Mechanism......................................... 163

4.4.5.2 Efficient Mirror Surface Finish by ELID-Lap Grinding.................................................................... 165

4.4.6 Desk-Top ELID-Lap Grinding System .................................. 166 4.4.6.1 Background............................................................... 166 4.4.6.2 Concept of the System ............................................. 167

4.4.7 Experimental System and Method.......................................... 168 4.4.7.1 Experimental System................................................ 168 4.4.7.2 Experimental Method ............................................... 168

4.4.8 Experimental Results .............................................................. 168 4.4.8.1 Grinding Characteristics of Cemented

Carbide Alloy ........................................................... 168 4.4.8.2 Grinding Characteristics of Nitrided Steel .............. 170 4.4.8.3 Grinding Characteristics of Sapphire....................... 172

4.4.9 Conclusions ............................................................................. 174 4.5 Materials, Experimental Setup, and Testing Procedure

(Study Case)........................................................................................ 174

Mariana Pruteanu

4.5.1 Materials.................................................................................. 174 4.5.1.1 Workpiece Materials ................................................ 174 4.5.1.2 Abrasives .................................................................. 177

4.5.2 Experimental Equipment and Lapping Setup ........................ 178 4.5.3 Testing Procedure ................................................................... 182

4.5.3.1 Lapping Setup........................................................... 182 4.5.3.2 Measuring Procedures .............................................. 184

4.6 Experimental Results and Discussion ................................................ 188

Mariana Pruteanu

4.6.1 Test A...................................................................................... 188 4.6.2 Test B ...................................................................................... 204 4.6.3 Summary of Test A and Test B.............................................. 211 4.6.4 Test C ...................................................................................... 212

4.6.4.1 Fractional Factorial Experiment............................... 214 4.6.5 Modeling of Lapping Process................................................. 235 4.6.6 Conclusions of the Case Study............................................... 242

References.................................................................................................... 244 Bibliography ................................................................................................ 246 Appendix A.................................................................................................. 249 Appendix B.................................................................................................. 261

Abrasive finishing processes are manufacturing methods used to produce surfaces

of desired characteristics with an adequate rate of surface generation. They operate

with wear-resistant abrasives in the surface generation process. Often, these

processes are described as ‘‘finishing methods using random cutting edges’’ [1].