Development of flexible polishing tools for synchro-speed polishing processes using additive manufacturing

Abstract

A new concept for synchro-speed polishing of flat and spherical surfaces is introduced: 3D printed gradient index (GRIN) polishing tools. By using additive manufacturing technologies in combination with photopolymer plastics, GRIN tools can be fabricated that are individually adapted to the workpiece geometry. By using two different plastics, the hardness and therefore the removal rate of certain tool areas can be defined. Surface structures, benefiting material removal rate and tool wear rate, are possible as well as lightweight structures with high mechanically stability. Tools can be fabricated as thin foils as well as solid pads, ranging from small (few mm) to large diameters. Additionally, the pads can be fabricated with an individual radius. This can enable the replacement of radius-dependent tool holders, because the pads can be mounted on flat tool interfaces, since the radius is not dependent from the tool body anymore. First results from the experimental setup are showing, that by using GRIN foils similar surface quality results can be achieved in comparison to conventional polyurethane foils, while the GRIN foils are offering a lot more possibilities regarding process optimization.