Simulation of abrasive insert distribution in a disc tool for micro-grinding

The paper presents the results of simulation analyses regarding the distribution of abrasive pellets in a tool for flat surface machining on a single-disc lapping machine. The analyzed abrasive-metal tool accounts for varying states of disc wear. Circular abrasive inserts with a diameter of 23 mm were used.1. INTRODUCTION
Nowadays, in the high-precision shaping of flat surfaces, alongside traditional mechanical or chemical-mechanical lapping, where the lap has a uniform structure (usually metal – cast iron, copper, steel, or aluminum, or possibly bimetallic – typically cast iron-copper), machining with abrasive-metal or abrasive tools (uniform and composite) is employed. This can also be referred to as micro-grinding or honing with lapping kinematics [2,3,5].
This machining is performed on both single- and double-disc lapping machines.
It is possible to use layered tools based on diamond or cubic boron nitride. However, uniform constructions are expensive, so other solutions are sought; this applies especially to discs with significant diameters. Lapping machines with large-scale tools allow for the simultaneous machining of a larger number of elements, but their cost then increases significantly. (…)

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