Abstract
In this study, an additive manufacturing process based on digital light processing was employed for a quick, flexible, and economical fabrication of resin bonded SiC grinding tools. The grinding wheel has been fabricated using laboratory manufacturing processes that utilize ultraviolet-curable resins and conventional abrasives. Also, desirable geometries and features like integrated coolant holes, which are difficult or even almost impossible to manufacture by conventional processes, are easily achievable. Grinding experiments were carried out by different process parameters, and with two different grinding wheels, i.e., with and without cooling channels with different concentrations (25 wt.% and 50 wt.% grains) to evaluate the grinding efficiency of the produced tools. Grinding forces, tool wear, tool loading, and ground surface quality were measured and analyzed. The wear rates of the grinding wheels with cooling channels were generally less than those without cooling channels, particularly in the deep grinding processes with large contact areas. Grinding tests on a hardened steel have shown that the integration of cooling lubricant channels almost prevents the wheel loading. In addition, by increasing the cutting speed (from 15 to 30 m/s) and decreasing the feed rate (from 10 to 2 m/min), the grinding wheel wear was significantly reduced. Furthermore, surface grinding of aluminum resulted in surface roughness values (Ra) in the range of 1 μm to 2.5 μm, while a Ra of about 0.2 μm was achieved by grinding hardened steel (100Cr6) with the same grinding conditions. Using the higher SiC-grain concentration (50 wt.%), it was determined that the surface roughness was 50% finer. Additionally the tool wear was significantly reduced (up to 30 times depending on the process parameters). The wear characteristics of the grinding wheel were analyzed through a novel image processing system. Significant correlations were found between the wear flat of grains and the increase in grinding forces due to the tool wear.
Highlights
Resin bonded abrasive cutting tools including grinding wheels, lapping plates, and even polishing pads are widely applied in industry due to their advantages in low process forces and self-sharpening properties [1]
The additive manufacturing (AM) process is known to be a flexible manufacturing process for complex geometries, and it has recently been developed with many novel applications in engineering
The grinding experiment demonstrated the performance of UV resinoid grinding wheels was significantly improved with the addition of particles
Summary
Resin bonded abrasive cutting tools including grinding wheels, lapping plates, and even polishing pads are widely applied in industry due to their advantages in low process forces and self-sharpening properties [1]. Int J Adv Manuf Technol part but gave details regarding selecting a corresponding AM process In this regard, AM technology has recently been the focus of several research studies as an alternative for the conventional manufacturing process of both metal bonded and resin bonded abrasive cutting tools. For the resin bonded cutting tools, Du et al [10] printed grinding wheels of polyamide (nylon) and diamond grains using a selective lasersintering process while investigating their properties. Common resins are phenol formaldehyde, novolac phenolics and especially those with added crosslinking agent (e.g., hexa-methylenetetramine), phenoplasts, aminoplasts, vinyl ester resins, alkyd resins, allyl resins, furan resins, epoxies, polyurethanes, cyanate esters, and polyimides [11] These materials have higher mechanical and thermal properties than thermoplastics. Photopolymers with or without particles hardened by stereolithography (UV resin) are able to efficiently fix the abrasive grains
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