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1

Lapping for mirror-like finish on cylindrical inner and end surfaces using the lathe with linear motor

Moe A. L., Tanabe I., Iyama T., Nasu F.

Journal of Machine Engineering

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2010

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Vol. 10, No. 1

13--25

EN

Lapping is an old traditional machining process that has been useful all along in the human history. Uniform surface finishing by manual hand lapping on cylindrical inner and end surfaces are very difficult. Additionally, the geometrical form accuracy and productivity are lower. In a previous study, the new lapping method for outer cylindrical surface using the lathe with linear motor has been reported. However, this method could not be applied directly for the cylindrical inner and end surfaces. Therefore, lapping for mirror-like finish on cylindrical inner and end surfaces using the lathe with linear motor is investigated. In this study, lapping tool was modified from previous study to be suited for the cylindrical inner and end surfaces. Then, lapping methods for inner and end surfaces were developed for uniform mirror-like finish. Surface roughness and geometrical form accuracy improvement were measured for both surfaces. The optimum conditions for high productivity and high quality mirror-like surfaces were investigated. It was concluded from the results that, the developed lapping system was able to process mirror-like surface on cylindrical inner and end surfaces. Moreover, the optimum conditions for the mirror-like surfaces were revealed experimentally.

2

High speed lapping for mirror-like finish using the lathe with linear motor

Moe A. L., Tanabe I., Iyama T., Nasu F.

Journal of Machine Engineering

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2010

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Vol. 10, No. 1

26--38

EN

Several machines with linear motor have been developed for high productivity. The characteristics of these machines are high speed, high acceleration and deceleration with stable behaviors of feed. Moreover, mirror-like surface is required to add high quality on the most products. In this study high speed lapping by using the lathe with linear motor was investigated for mirror-like surface. Lapping was performed after turning with the same lathe Lapping tool consists of a lapping head, a spring and holder on the tool post to assemble the linear motor lathe. The spring is used to supply lapping pressure. Lapping slurry consists of water, PEO ( Polyethylene Oxide) and diamond grain. This slurry was supplied between a work piece and lapping head. Then, high speed lapping was performed. During the process, the lapping head temporarily left from work surface in order to catch some new grains and removed some chips. The optimum combination of both the spindle speed and the feed speed was investigated for high quality and productivity experimentally. Surface roughness and form accuracy were measured. It was concluded from the results that (1) Mirror-like surface was obtained by the high speed lapping, and (2) Optimun conditions for efficient high speed lapping was revealed experimentally.

3

Development of intelligent lapping system estimation of finished surface roughness and its improvement speed

Iyama T., Tanabe I., Moe A. L., Yoshi K., Nasu F.

Journal of Machine Engineering

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2010

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Vol. 10, No. 1

5--12

EN

The lapping process is one of the traditional finishing processes and generally it is conducted as manual process by skilled worker. The productivity of these manual processes is lower and difficult to control. Hence, we developed an automatic lapping system for moulds and dies. The lapping system consists of simple lapping tools and conventional milling machine. Several materials were machined as mirror like surface using the system. The lapping conditions are usually decided by skilled worker's experience or knowhow. Therefore, in this study, an intelligent lapping system with the optimum conditions calculated by the lapping model was developed. Specifically, the relationship between the finished quality (surface roughness Rz and improvement rate of Rz) and each parameter of the system, Vickers hardness of work piece and lapping head, lapping pressure, grain size, is investigated. Then, an intelligent lapping system is developed. Finally, the HPM31 are machined as confirmatory experiment by developed system with calculated lapping conditions. It is concluded from the result that: (1) The relationship between the surface roughness and lapping parameter was cleared. (2) The intelligent lapping system using the lapping model was developed. (3) The estimated limit surface roughness and improvement rate by calculated condition satisfactorily agreed with the experimental results.