Research on composite pattern design and lapping performance of fixed abrasive pads controlled by multi-physical fields

The present work provides an innovative method of composite pattern design for fixed abrasive pads, addressing issues such as machining non-uniformity and passivation blockage arising from uneven lapping flow, pressure, and velocity fields in lapping. First, a multi-physical field modeling method is provided, a material removal distribution model and evaluation criteria for the performance of the abrasive pad are established, and the reliability of this model is validated. Second, based on the model, a composite pattern abrasive pad coupled with a spiral groove and concentric micro groove is designed. Comparative experiments are conducted with the grid abrasive pad. The results show that the clogging and passivation performance of the composite pattern abrasive pad is improved, and the pressure distribution is optimized. Compared with the grid abrasive pad, in the pressure range of 20 N–70 N, the surface roughness Ra of sapphire is reduced by 6.4 %–25.42 %, defects such as brittle fracture pits and scratches on the workpiece surface are reduced, and the surface quality of the workpiece is significantly improved. The material removal rate is between 0.23 μm/min to 0.34 μm/min. This confirms the effectiveness of optimizing abrasive pad pattern design based on multi-physics fields. The research results provide a novel approach for abrasive pad pattern design with engineering application value.