Single-sided lapping is one of the most effective planarization technologies. The process has relatively complex kinematics and it is determined by a number of inputs parameters. It has been noted that prediction of the tool wear during the process is critical for product quality control. To determine the profile wear of the lapping plate, a computer model which simulates abrasive grains trajectories was developed in MATLAB. Moreover, a data-driven technique was investigated to indicate the relationship between the tool wear uniformity and lapping parameters such as the position of conditioning rings and rotational speed of the lapping plate and conditioning rings.

The lapping process is strongly affected by a number of input parameters. One of the fundamental mechanical processes in lapping is the abrasive effect of particles. In order to examine the influence of the kinematic parameters on the lapping uniformity of unconventional single-sided machine, numerical simulations of particles sliding trajectories are performed. Changing the kinematic parameters, e.g., rotational velocities or position of the conditioning rings together with the workpieces can be used for correcting the profile of an active surface of the lap. This paper provides a basic guide to the kinematic parameter settings of single-sided lapping process. Furthermore, an unconventional single-sided lapping system, where a conditioning ring performs additional motion during the machining, is described. Simulation results show that the rotational speed ratio of the conditioning ring to the lapping plate k 1 and the period ratio of the reciprocating motion to the lapping plate rotary motion k 2 represent the relationships among the three basic motions of unconventional lapping systems and are major factors affecting trajectory distribution. Material removal rate and trajectory density parameter are proposed to optimize the kinematic parameters for better uniformity of lapping plate wear. The preferred kinematic parameter values for single-sided lapping system with reciprocating motions and the assumed size of the machine are k 1 = 0, 78 and k 2 = 2. The general results were validated on a specially designed test stand.

Przedstawiono wpływ wybranych parametrów kinematycznych na geometryczne wyniki procesu docierania 1-tarczowego. W celu poprawy płaskości oraz jakości obrabianych powierzchni przeprowadzono optymalizację tych parametrów. Podstawowym kryterium optymalizacji jest równomierność zużycia narzędzia. Zaprezentowano wyniki symulacji, a następnie porównano je z wynikami badań eksperymentalnych. SŁOWA KLUCZOWE: docieranie 1-tarczowe, kinematyka docierania, zużycie ścierne, optymalizacja parametrówIn this paper the influence of selected kinematic parameters on the geometrical results of the single-sided lapping process was presented. The purpose of parameters optimization is to improve the flatness and quality of the machined surfaces. The basic optimization criterion is the uniformity of tool wear. The simulation and experimental results were presented and compared.

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Previous studies on one-sided lapping allow to state that not only parameters of lapping elements (i.e. properties of workpiece, abrasive grains and lapping plate) impact on a lapping efficiency. Influential are also kinematics and dynamics of the process. It is crucial to control an average velocity of lapping (v), a distribution of tangential acceleration (at), a nominal pressure (p), a lapping time (t) and disposal of workpiece in separator.Based on kinematics equations and the tribological models, the dimensionless distribution of the material removal volume and the trajectories of abrasive grains cutting on the lap were numerically simulated. Obtained information about excessive wear on lapping plate was the starting point to work out non-standard, single-plate lapping systems.In this paper ideas of unconventional lapping systems were presented. After numerous simulations and careful analysis it was observed, that the most desirable system is radial lapping system. It was point out that other systems are not very different from the standard kinematic system. Generated trajectories of an abrasive grain were almost identical. What is more, effects of kinematical parameters on the trajectories, velocities and accelerations observed in radial lapping system are shown.