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Lapping, sometimes referred to as free abrasive machining, is a precision machining process used to achieve component flatness, parallelism, size and surface finishes to incredibly demanding tolerances.

The process employs the use of a lapping medium (a fluid vehicle and abrasive) to erode stock from a surface. It differs from Grinding, as this process has the abrasive fixed/bonded into the grinding wheel. The lapping process results in a matt surface finish, which is the effect of the abrasive particles rolling randomly between the lapping plate and component. Abrasives are added to a liquid and agitated to keep the particles in a suspension. This is called a slurry.

When surfaces that require absolute precision need to be produced, lapping is the go-to method for achieving extreme flatness, parallelism, and surface finish by going way beyond conventional machining techniques. This process is typically very slow and controlled, thus enabling the production of dimensions to a very high degree of accuracy. Clamping is not required for lapping, as the workpiece rests on the lapping wheel under its own weight, therefore avoiding clamping distortion.

Additional weights or pressure can be added to help with stock removal. It’s possible to process a vast range of material types with minimal setup. It lends itself particularly well to non-magnetic products.

As with abrasive and vehicle selection, varying the lapping pressure will produce a heavier or lighter stock removal rate and a rougher or finer surface finish. By applying the care and attention appropriate to a precision machining process, fine lapping is capable of producing tolerances as precise as those listed below (based on a 100mm x 10mm thick steel disc):

• Flatness: 1 sodium light band (0.00029mm)*
• Parallelism: 0.0005mm
• Size: 0.001mm
• Surface finish: 0.1um Ra
• *to check with light bands, a surface must be reflective (indicative of a lapped and polished components)

Our clients come from a wide variety of industries from aerospace and motorsport to marine and nuclear. We’re always on the lookout for our next challenge.

If you have any questions about us, the services we offer, or more importantly, how we can help you, get in touch with us today.