Selective laser sintering and grinding performance of resin bond diamond grinding wheels with arrayed internal cooling holes

Du, Zhi-jun; Zhang, Fenglin; Xu, Qiong-sheng; Huang, Yao-jie; Li, Mingcong; Huang, Huiping; Wang, Chengyong; Zhou, Yumei; Tang, Hongqun

doi:10.1016/j.ceramint.2019.07.076

Cited by 33 publications

(15 citation statements)

References 21 publications

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“…As presented in [ 102 ], this method was used in the production of components with high mechanical properties and complex structures, such as porous polyamide mold for pressure slip casting. Du et al [ 103 ] proposed the SLS method for manufacturing resin bond diamond grinding wheels with internal cooling holes. The results from grinding glass indicated that the grinding force decreases with increasing cooling hole diameter.…”

Section: Application Of Am Technologies In Abrasive Machiningmentioning

confidence: 99%

Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

et al. 2021

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High requirements imposed by the competitive industrial environment determine the development directions of applied manufacturing methods. 3D printing technology, also known as additive manufacturing (AM), currently being one of the most dynamically developing production methods, is increasingly used in many different areas of industry. Nowadays, apart from the possibility of making prototypes of future products, AM is also used to produce fully functional machine parts, which is known as Rapid Manufacturing and also Rapid Tooling. Rapid Manufacturing refers to the ability of the software automation to rapidly accelerate the manufacturing process, while Rapid Tooling means that a tool is involved in order to accelerate the process. Abrasive processes are widely used in many industries, especially for machining hard and brittle materials such as advanced ceramics. This paper presents a review on advances and trends in contemporary abrasive machining related to the application of innovative 3D printed abrasive tools. Examples of abrasive tools made with the use of currently leading AM methods and their impact on the obtained machining results were indicated. The analyzed research works indicate the great potential and usefulness of the new constructions of the abrasive tools made by incremental technologies. Furthermore, the potential and limitations of currently used 3D printed abrasive tools, as well as the directions of their further development are indicated.

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Section: Application Of Am Technologies In Abrasive Machiningmentioning

confidence: 99%

Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

et al. 2021

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“…Yang et al [9] also developed an additive manufacturing (AM) technology to fabricate metal bonded diamond grinding wheels with regular grain distribution. For the resin bonded cutting tools Du et al [10] printed grinding wheels of polyamide (nylon) and diamond grains using a selective laser-sintering process while investigating their properties. The results indicated a good adhesion of plastics but also showed the problem of nylon melting during the grinding process and forming a smearing layer on the ground surface.…”

Section: Introductionmentioning

confidence: 99%

“…Such tools have been proved to have substantial advantages over conventional abrasive tools [16,17]. Guo und Du et al [10,18] used a strong ultravioletcurable resin bond for a diamond lapping plate and compared it with a conventionally manufactured lapping plate. The results showed not only a higher material removal rate but also a ner surface.…”

Section: Introductionmentioning

confidence: 99%

Digital light processing based additive manufacturing of resin bonded SiC grinding wheels and their grinding performance

Khosravi

Azarhoushang

et al. 2021

Preprint

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In this study, an additive manufacturing process based on digital light processing was employed for 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 was analyzed through a novel image processing system. Significant correlations were found between wear flat of grains and the increase in grinding forces due to the tool wear.

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“…Resin lapping wheels containing diamond abrasive grains enabled performing effective machining of hard and brittle ceramic materials [25,26]. Tools fabricated by selective laser sintering (SLS) can find application in grinding [27] or in lapping.…”

Section: Introductionmentioning

confidence: 99%

A Pilot Study on Machining Difficult-to-Cut Materials with the Use of Tools Fabricated by SLS Technology

Deja

Zieliński

2021

Materials

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The growing use of contemporary materials in various industrial sectors, such as aerospace, automotive, as well as the oil and gas industry, requires appropriate machining methods and tools. Currently, apart from the necessity to obtain high-dimensional and shape accuracy, the efficiency and economic aspects of the selected manufacturing process are equally important, especially when difficult-to-cut materials, such as hard and brittle ceramics, have to be machined. In the research presented in this paper, a prototype tool fabricated from polyamide powder by the SLS method was used in flat-lapping of Al2O3 ceramics, showing the promising potential and efficacy of rapid tooling and manufacturing in the area of abrasive machining. The influence of the selected input process factors, such as machining time, the type of abrasive suspension, kinematic parameters, and unit pressure, on technological effects, was analyzed. The microscopic observations of the active surface of the prototype tool showed its reinforcement with loose diamond abrasive particles (size D107), resulting in the effective material removal and improved surface finish of Al2O3 ceramic samples. The directions for further development of tools fabricated by the SLS method for applications in abrasive machining were also envisaged by the authors.

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Selective laser sintering and grinding performance of resin bond diamond grinding wheels with arrayed internal cooling holes

Cited by 33 publications

References 21 publications

Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

Digital light processing based additive manufacturing of resin bonded SiC grinding wheels and their grinding performance

A Pilot Study on Machining Difficult-to-Cut Materials with the Use of Tools Fabricated by SLS Technology

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