Lapping is a machining process with a geometrically indeterminate cutting edge and loose grain bound in a lapping mixture. This lapping mixture is introduced into the gap between the workpiece, which moves relative to each other, and the lapping wheel. The workpiece surface is machined by the undirected movement of the lapping grains, which alternates between rolling and sliding. However, the complex processes in the contact and the relationship between the process parameters and the movement of the lapping grains are not yet sufficiently understood. Fundamental numerical and experimental investigations should provide a deeper understanding of the process with regard to particle kinematics and the contact processes.

As part of this research project, the Chair of Applied Structural Mechanics is creating an FEM simulation of the material removal as a partial simulation of the lapping process. In parallel, DEM simulations will be set up to investigate the movement behavior of the loose lapping grains and CFD simulations will be developed to describe the flow behavior of the lapping liquid.

Finally, all of the above simulations are coupled to form the lapping process model. All basic models and the lapping process model are validated by experiments. The validated lapping process model is used to make predictions about the surface quality of the lapped workpiece for selected process parameters. The variable parameters include: the relative speed between the tool and the workpiece, the viscosity of the lapping liquid, the duration of the lapping process and the number, size and geometry of the lapping grains.