Abstract
Brushing with bonded abrasives is a flexible finishing process used for the deburring and the rounding of workpiece edges as well as for the reduction of the surface roughness. Although industrially widespread, insufficient knowledge about the contact behavior of the abrasive filaments mainly causes applications to be based on experiential values. Therefore, this article aims to increase the applicability of physical process models by introducing a new prediction method, correlating the contact forces of single abrasive filaments, obtained by means of a multi-body simulation, with the experimentally determined process forces of full brushing tools during the surface finishing of ZrO2. It was concluded that aggressive process parameters may not necessarily lead to maximum productivity due to increased tool wear, whereas less aggressive process parameters might yield equally high contact forces and thus higher productivity.
Highlights
Brushing with bonded abrasives is an industrial manufacturing process, which is predominantly used for the deburring and rounding of metallic workpiece edges
This article aims to increase the applicability of physical process models by introducing a new prediction method, correlating the contact forces of single abrasive filaments, obtained by means of a multi-body simulation, with the experimentally determined process forces of full brushing tools during the surface finishing of ZrO2
The advantages of brushing with bonded abrasives are based on the high flexibility of the abrasive filaments, which allow for the adaptation to complex workpiece geometries, despite ordinarily shaped tools, and the compensation of small geometric deviations of tools, workpieces and machine systems, as well as tool trajectories
Summary
Brushing with bonded abrasives is an industrial manufacturing process, which is predominantly used for the deburring and rounding of metallic workpiece edges. It has gained importance in the finishing of technical surfaces, mainly for the reduction of the surface roughness [1,2,3]. The process is characterized by its flexible brushing tools (Figure 1), usually consisting of a cast epoxy brush body, to which abrasive filaments are attached (Figure 1a). These are composed of an extruded polymer matrix, normally polyamide 6.12, and bonded abrasive grains, normally silicon carbide (SiC) or aluminum(III) oxide (Al2O3). A considerable disadvantage of the process is the insufficient knowledge of the motion, the chipping, and the wear behavior of the abrasive filaments, with the result that industrial processes are typically based on experiential values, making predictions for new processes difficult [1,5,6]
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