A predictive model for tool wear behavior during ultra-precision lapping.

Ultra-precision lapping is widely used in the mass production of various types of high-precision bearing rollers. The lapping quality of the bearing rollers is greatly influenced by the wear behavior of the lapping tool. In this context, this study presents a computational analysis utilizing the Archard wear law and finite element modeling (FEM) to examine the wear behavior of the lapping tool. A wear simulation approach based on the Archard wear law is implemented in the ABAQUS software that works in association with the Arbitrary Lagrange Eulerian adaptive mesh technique and the Umeshmotion subroutine. Initially, the parameters of the Archard wear model are investigated experimentally using the free abrasive lapping device. A numerical 3D finite element model is established in order to obtain the contact pressure distribution, wear volume, wear depth, and wear profile of the lapping tool. The mesh within the wear region of the finite element model is allowed to move independently from the material to maintain the high-quality mesh for simulating material removal. The simulation efficiency is improved by the incorporation of an acceleration factor. Ultimately, the lapping tool is subjected to an examination regarding the contact pressure distribution, wear depth, and alterations in the wear profile. The wear simulation results of the lapping tool can provide significant insights for future run-in and machining processes. [ABSTRACT FROM AUTHOR]