HIGHLY EFFICIENT AND ACCURATE MIRROR FINISH OF METAL MOLDS BY USE OF FIGURE-8 TOOL MOTION GENERATED BY A THREE-DIMENSIONAL TOOL OSCILLATION SYSTEM

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Complicated shape molds are generally processed by die-sinking EDM and then finished by hand lapping. In order to enhance the efficiency and accuracy in manufacturing metal molds, a lapping machine, which can apply three-dimensional tool motions to a lapping tool, was developed and its fundamental lapping performance was investigated. As a result, the following things became clear. (1) Larger form collapse arises in a lapped surface by three-dimensional figure-8 tool motion while good surface roughness is obtained. (2) Form collapse of a lapped surface becomes small when circular tool motion with a central axis parallel to the work feed direction is used.