Establishment of material removal model for lapping ceramic balls with variable-radius groove plate
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ORIGINAL ARTICLE
Establishment of material removal model for lapping ceramic balls with variable-radius groove plate Fenfen Zhou 1 & Weifeng Yao 2 & Julong Yuan 3 & Fan Li 3 & Binghai Lyu 3 & Ping Zhao 3 Received: 28 May 2020 / Accepted: 15 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Lapping ceramic balls with variable-radius groove plate (VRGP) has obvious advantages in achieving good consistency of batch manufacturing of ceramic balls. The material removal model of a single ball was established based on Hertz contact theory. Then, combining the previous research works based on kinematic analysis and the material removal model, the forming process of single ball was simulated and evaluated by the deviation from spherical form (ΔSph). After lapping period of 10 h, the experimental deviation of ΔSph decreases from about 0.233 to 0.0324 μm, and its maximum error between experimental and simulation values is 17.7%, indicating that the simulation results of variation of ΔSph with time were mostly consistent with the experimental results. The validity of material removal model of lapping ceramic balls was verified experimentally. Keywords Ceramic balls . Material removal model . Deviation from spherical form . Preston’s formula
1 Introduction Ceramic ball with low density, high hardness, high stiffness, wear resistance, low thermal expansion coefficient, and other excellent comprehensive performance is considered to be the most ideal rolling body for high speed and high precision bearings [1, 2]. However, due to the hard and brittle characteristics of ceramic balls, the lapping process is timeconsuming and expensive. In order to improve the lapping precision and efficiency of ceramic balls, researchers have developed a series of lapping methods, such as magnetic fluid (MF) grinding [3, 4], magnetic fluid support (MFS) grinding [5, 6], eccentric v-groove (EV) lapping [7], three rotating plates (TRP) lapping [8], dual rotating plates (DRP) lapping * Fenfen Zhou [email protected] * Weifeng Yao [email protected] 1
School of Intelligent Manufacturing, Taizhou University, No. 1139, Shifu Road, Taizhou City 318000, Zhejiang Province, China
2
School of Mechanical and Electrical Engineering, Shaoxing University, No. 508, West Huancheng Road, Shaoxing City 312000, Zhejiang Province, China
3
Ultra-precision Machining Center, Zhejiang University of Technology, No. 18, Chaowang Road, Hangzhou 310014, China
[9], and variable-radius v-groove (VV) lapping [10]. More precise theoretical analysis can guide experiments and reduce the number of experiments. At present, the theoretical research on these lapping methods mainly focuses on two aspects: lapping trajectory analysis based on kinematics and material removal mechanism. By kinematics, Zhang et al. analyzed the lapping trajectory in traditional concentric v-groove lapping and obtained that the lapping trajectory is a fixed circle on the ball surface [11]. Lee et al. defined the lapped area ratio to characterize the dense of the distr
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