Investigation and optimization flat lapping process using non-dominated sorting genetic algorithm II

Lapping process is one of the most important polishing processes in order to achieve a flat surface. In this paper, effects of parameters such as abrasive particle size, abrasive particles concentration in slurry, and lapping pressure on material removal rate, flatness and surface roughness were investigated in single sided lapping of flat workpieces made of 440c steel. To conduct experiments, Lapmaster 15 lapping machine has been exerted. The most important problem in lapping process is the low material removal rate which cause increase cost and production time. Therefore, in the lapping process, the selection of conditions that in addition to the production of pieces with geometric accuracy and surface roughness needed have a high material removal rate, is very important. In this paper, for the first time, the material removal rate, surface roughness and flatness lapped pieces have been optimized using non-dominated sorting genetic algorithm II (NSGA II) and, the Pareto optimal solutions were obtained. The results show that NSGA II is a useful and powerful tool for optimizing the material removal rate, surface roughness and flatness lapped pieces. Using this optimization algorithm, pieces with surface roughness and flatness requirements can be produced at high material removal rate. As a result, with this optimization algorithm, in addition to creating optimal quality parts, the production cost and time are reduced.