Study on machining performance of fixed-abrasive lap-grinding plate with random grid structure

To meet the increasing requirements on material removal efficiency, surface quality, and subsurface damage in the ultra-precision grinding process, a textured-fixed abrasive plate (T-FAP) with random grid structure based on the Voronoi Diagram is proposed. The abrasive tool is fabricated by using UV-curable resin and micro-level alumina abrasive grains. The influence of time-varying texture characteristics of surface wear on the machining performance is studied via MATLAB image analysis and numerical simulation of the grinding trajectory. The lap-grinding experiment of the aluminum workpieces is carried out to analyze the material removal efficiency and workpiece surface roughness obtained from the T-FAP grinding process. The results show that the surface roughness of the workpiece processed with the T-FAP grinding is 0.84 μm, and that the material removal rate is 3.21 μm/min. Compared with the traditional fixed abrasive grinding tool, the T-FAP grinding ensures the material removal efficiency and obtains high surface accuracy as well