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<p>Polycrystalline ZnS tends to develop cracks and subsurface damage (SSD) during precision machining, which deteriorates its optical performance. To investigate crack evolution in fixed abrasive lapping of ZnS, an integrated approach combining analytical modeling, numerical simulation, and experimental evaluation was developed. An analytical model was first developed to relate cutting depth to applied pressure for a single dodecahedron-shaped abrasive. Microscopic parameters were then calibrated to ensure consistency between the contact model response and macroscopic mechanical properties of the material using discrete element method (DEM). The calibrated model was used to simulate the lapping process, showing that both crack density and SSD depth increased with applied load. Compared with spherical abrasives, dodecahedral abrasives produced SSD depths that closely matched experimental measurements, with a maximum relative error of 14.79% occurring under the processing condition of 60&#xa0;rpm platen speed, 50&#xa0;rpm carrier speed, 10&#xa0;min lapping time, and a lapping pressure of 51474.65&#xa0;Pa. Tensile stress was identified as the primary driver of crack formation, whereas shear stress contributed only marginally to the overall damage. Moreover, a saturation trend in damage evolution was observed at a cutting depth of 608.26&#xa0;μm, indicating a threshold beyond which further crack formation is limited. The proposed approach establishes a practical framework for damage prediction and provides a tool for guiding the machining of brittle materials.</p> Graphical Abstract <p></p>

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Modeling and Simulation of Crack Evolution in ZnS Fixed Abrasive Lapping Using Discrete Element Method

  • 期刊论文

  • 发表日期：

    2026年1月6日

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  • Song Sha,
  • Yanjun Guo,
  • Xiaojing Yang,
  • Yafei Qin,
  • Ao Zhang,
  • Guangzhao Li

摘要

Polycrystalline ZnS tends to develop cracks and subsurface damage (SSD) during precision machining, which deteriorates its optical performance. To investigate crack evolution in fixed abrasive lapping of ZnS, an integrated approach combining analytical modeling, numerical simulation, and experimental evaluation was developed. An analytical model was first developed to relate cutting depth to applied pressure for a single dodecahedron-shaped abrasive. Microscopic parameters were then calibrated to ensure consistency between the contact model response and macroscopic mechanical properties of the material using discrete element method (DEM). The calibrated model was used to simulate the lapping process, showing that both crack density and SSD depth increased with applied load. Compared with spherical abrasives, dodecahedral abrasives produced SSD depths that closely matched experimental measurements, with a maximum relative error of 14.79% occurring under the processing condition of 60 rpm platen speed, 50 rpm carrier speed, 10 min lapping time, and a lapping pressure of 51474.65 Pa. Tensile stress was identified as the primary driver of crack formation, whereas shear stress contributed only marginally to the overall damage. Moreover, a saturation trend in damage evolution was observed at a cutting depth of 608.26 μm, indicating a threshold beyond which further crack formation is limited. The proposed approach establishes a practical framework for damage prediction and provides a tool for guiding the machining of brittle materials.

Graphical Abstract