Formation mechanism of concave and convex surface shapes in double-sided lapping.

Double-sided lapping process is a key technology for obtaining high efficiency and flatness in fabricating plane-parallel workpiece surfaces, such as wafers, optical windows, seal rings, etc. However, the formation of the concave and convex surface shapes of workpieces was rarely investigated in the previous research, and the mechanism was unknown. This paper establishes a new kinematic model to clarify the formation mechanism of concave and convex surface shapes, in which the workpiece eccentricity and rotation in the planetary wheel are considered for the first time. The measurement and control method of workpiece rotational speed in the planetary wheel is proposed. The formation of the concave and convex surface shapes is validated experimentally by adjusting the rotational speed of the workpiece, and the results show a good consistency with the calculation results. A flatness error convergency method is proposed based on the surface shape formation mechanism, and flatness superior to 5 µm is achieved on Φ200 × 2 mm thin copper substrates. [Display omitted] • The formation mechanism of convex and concave surface shapes is clarified. • Workpiece's eccentricity and rotation are supplemented to general kinematic model for the first time. • The measurement and control methods for workpiece rotational speed are developed. • A flatness error convergency method is proposed. • Flatness superior to 5 µm is achieved on Φ200 × 2 mm thin copper substrates. [ABSTRACT FROM AUTHOR]