Tribological surface and lapping method and system therefor

Abstract

A mechanical system for lapping a metal working surface, including: (a) a workpiece having the metal working surface; (b) a lapping tool having a contact surface, the contact surface for disposing generally opposite the working surface, the contact surface including an organic, polymeric material; (c) a plurality of particles, including abrasive particles, the abrasive particles for disposing between the contact surface and the working surface, and (d) a mechanism, associated with at least one of the working and contact surfaces, for applying a relative motion between the contact surface and the metal working surface, and for exerting a load on the contact surface and the working surface, the contact surface for providing an at least partially elastic interaction with the plurality of abrasive particles, and wherein the contact surface and the mechanism are designed and configured, and the plurality of particles is selected, such that upon activation of the mechanism, the relative motion under the load effects: (i) lapping of the metal working surface, and (ii) incorporation of particles into the metal working surface.

1 . A mechanical system for lapping a metal working surface, the system comprising:
 (a) a workpiece having the metal working surface;   (b) a lapping tool having a contact surface, said contact surface for disposing generally opposite the working surface, said contact surface including an organic, polymeric material;   (c) a plurality of particles, including abrasive particles, said abrasive particles for disposing between said contact surface and the working surface, and   (d) a mechanism, associated with at least one of the working surface and said contact surface, for applying a relative motion between said contact surface and the metal working surface, and for exerting a load on said contact surface and the working surface,   said contact surface for providing an at least partially elastic interaction with said plurality of abrasive particles,   and wherein said contact surface and said mechanism are designed and configured, and said plurality of particles is selected, such that upon activation of said mechanism, said relative motion under said load effects:
 (i) lapping of the metal working surface, and 
 (ii) incorporation of particles into the metal working surface. 
   
   
   
       2 . The mechanical system of  claim 1 , wherein said contact surface has a Shore D hardness within a range of 40-90. 
   
   
       3 . The mechanical system of  claim 2 , wherein said Shore D hardness is within a range of 60-90. 
   
   
       4 . The mechanical system of  claim 2 , wherein said Shore D hardness is within a range of 65-90, and wherein said impact resistance is within a range of 4-12 kJ/m 2 . 
   
   
       5 . The mechanical system of  claim 4 , wherein said Shore D hardness is within a range of 68-82. 
   
   
       6 . The mechanical system of  claim 4 , wherein said Shore D hardness is within a range of 68-82, and wherein said impact resistance is within a range of 5-8 kJ/m 2 . 
   
   
       7 . The mechanical system of  claim 1 , wherein said abrasive particles are freely disposed between said contact surface and said working surface. 
   
   
       8 . The mechanical system of  claim 4 , wherein said polymeric material includes an epoxy material. 
   
   
       9 . The mechanical system of  claim 4 , wherein said polymeric material includes polyurethane. 
   
   
       10 . The mechanical system of  claim 1 , wherein a composition of said contact surface includes an epoxy material and polyurethane in a weight ratio of 25:75 to 90:10. 
   
   
       11 . The mechanical system of  claim 1 , wherein a composition of said contact surface includes polyurethane in a range of 3% to 75%, by weight. 
   
   
       12 . The mechanical system of  claim 1 , wherein said contact surface and said mechanism are further designed and configured, and said plurality of particles is selected, such that said incorporation provides an organic nanolayer intimately bonded to at least a portion of the metal working surface. 
   
   
       13 . The mechanical system of  claim 1 , wherein said contact surface and said mechanism are further designed and configured, and said plurality of particles is selected, such that upon activation of said mechanism, said relative motion under said load effects:
 (iii) incorporation of a portion of said abrasive particles into the metal working surface.   
   
   
       14 . The mechanical system of  claim 12 , wherein said contact surface and said mechanism are further designed and configured, and said plurality of particles is selected, such that upon activation of said mechanism, said relative motion under said load effects:
 (iii) incorporation of a portion of said abrasive particles into said organic nanolayer.   
   
   
       15 . The mechanical system of  claim 1 , wherein said contact surface is disposed on a lapping tool. 
   
   
       16 . The mechanical system of  claim 15 , wherein said lapping tool has a leading device associated therewith, said leading device for effecting an engagement of said lapping tool. 
   
   
       17 . The mechanical system of  claim 16 , wherein said leading device is associated with said lapping tool so as to provide said lapping tool with at least one degree of freedom of movement with respect to the metal working surface. 
   
   
       18 . The mechanical system of  claim 15 , wherein said lapping tool has an internal tube for delivering a working agent from an external supply to a volume between said contact surface and the working surface. 
   
   
       19 . The mechanical system of  claim 12 , wherein said organic nanolayer has an average thickness of less than 25 nanometers. 
   
   
       20 . The mechanical system of  claim 12 , wherein said organic nanolayer has an average thickness of less than 15 nanometers. 
   
   
       21 . The mechanical system of  claim 12 , wherein said organic nanolayer has an average thickness of less than 10 nanometers. 
   
   
       22 . The mechanical system of  claim 1 , wherein the metal working surface has a Rockwell C hardness of at least 20. 
   
   
       23 . A mechanical system for lapping a metal working surface, the system comprising:
 (a) a workpiece having the metal working surface;   (b) a lapping tool having a contact surface, said contact surface for disposing generally opposite the working surface, said contact surface including an organic, polymeric material;   (c) a plurality of particles, including abrasive particles, said abrasive particles for disposing between said contact surface and the working surface, and   (d) a mechanism, associated with at least one of the working surface and said contact surface, for applying a relative motion between said contact surface and the metal working surface, and for exerting a load on said contact surface and the working surface,   said contact surface for providing an at least partially elastic interaction with said plurality of abrasive particles,   and wherein said contact surface and said mechanism are designed and configured, and said plurality of particles is selected, such that upon activation of said mechanism, said relative motion under said load effects:
 (i) lapping of the metal working surface, and 
 (ii) incorporation of inorganic particles into the metal working surface, 
   
     said inorganic particles having a Mohs hardness of at least 8.