Effects of mixed abrasive grits in slurries on free abrasive machining (FAM) processes

Effects of mixed abrasive grits in slurries on free abrasive machining (FAM) processes are studied using a single-sided lapping machine. Impacts of mixing abrasives on various parameters such as amount of material removed, material removal rate, surface roughness, particle size distribution and relative angular velocity are studied. The material removed is monitored as a function of time. The experimental results suggest that (i) mixing abrasive grits can increase the amount of material removed, (ii) smaller abrasives can directly or indirectly affect the material removal process, (iii) slurries undergo severe grain size transition during lapping, and (iv) the surface roughness did not change significantly under different loading. The results of this study may have profound implication on the FAM processes that practitioners use today because the mixed abrasive grits increase material removal rate and reduce the grain size transition, while rendering similar surface roughness.