Abstract: Oriented to the high hardness mould free-form surface, a new method based on the softness consolidation abrasives (SCA) is brought forward. The key words ‘softness consolidation abrasives’ mean the abrasives group is bond to the rubber bonnet by the polymer binder. Compared with free abrasives used in other polishing methods, it can get more stable support from nearby polymer to form effective cutting. The flexibility is propitious to achieve large contact between tools and workpiece. Combined with the lays elastic theory, the passing force is analyzed, and a cutting model of single abrasive is established. Hardness of abrasive is brought into the modified Preston equation as an important factor. A cutting empirical formula is obtained for the stress lag in the softness situation. The estimable model of material removal is given by the numerical simulations of stress and velocity. The empirical results show the modified Preston equation is propitious to avoid errors for calculation.

Key words: Efficient, High hardness surface of mold, Pneumatic wheel, Preston equation, Softness-consolidation abrasives