Prediction of surface roughness improvement and its limitation in automated precision mold lapping

Abstract

Lapping is a precise machining process that can produce very high surface qualities and form accuracies simultaneously. Additionally, automated lapping is one of the best methods for today manufacturing industries in term of quality and productivity. However, over lapping can hinder to maintain higher form accuracies. The surface roughness and form accuracies of mold are crucial for optical lens manufacturing. Hence, this study aims to predict the limit surface roughness and process time in mold lapping process. At first, the physical parameters of grains are investigated by optical microscope. Then, the desired parameters are examined numerically based on lapping theory and regression model respectively. Finally, limit surface roughness and process time can be predicted successfully to maintain higher form accuracy in precision mold finishing.