Examination of the material removal mechanisms during the lapping process of advanced ceramic rolling elements

Two types of HIPed Si3N4 bearing ball blanks with different surface hardness and fracture toughness were lapped under various loads, speeds, and lubricants using a novel eccentric lapping machine. The lapped surfaces were examined by optical microscope and SEM. The experimental results show that the material removal rate for type 1 ball blanks were 3–4-fold of type 2 in most cases. Different lapping fluids affected the material removal rate at lower lapping loads, but they had much less influence on the material removal rate at higher lapping loads. The SEM micrographs reveal that the grain pullout prevailed on the lapped surface of type 1 ball blanks, and the surface of type 2 featured bulk material removal by microcracking. Under extreme high lapping load, surface cracks and damages were found, and SEM with EDX disclosed steel from the lapping plate had transferred to the ceramic ball surface. The preliminary conclusion is that the material removal mechanism during the lapping process of silicon nitride balls using this eccentric lapping machine is mainly mechanical abrasive wear. Lawn and Wilshawʹs indentation model on brittle materials is used to explain the difference in material removal rate for the two types of ball blanks.