A feasibility study on SLS-fabricated polyamide tools in double-sided precision machining of technical oxide ceramics Al2O3
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1
Department of Manufacturing and Production Engineering, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdansk, Poland
2
Doctoral School at Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdansk, Poland
3
Institute for Machine Tools and Factory Management, Technische Universität Berlin, Pascalstraße 8-9, 10587 Berlin, Germany
4
Institute for Machine Tools and Factory Management, Technische Universität Berlin, Pascalstraße 8-9, 10587 Berlin, Germany
Fraunhofer Institute for Production Systems and Design Technology IPK, Pascalstraße 8-9, 10587 Berlin, Germany
Corresponding author
Dawid Zieliński
Department of Manufacturing and Production Engineering, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdansk, Poland
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ABSTRACT
The significance of lapping process lies in its ability to achieve precise surface quality and dimensional accuracy on the workpiece. Apart multiple controlled and uncontrolled process factors, the lapping tool type and its characteristics play critical role in the process efficiency. Additive manufacturing (AM) recently attracted considerable attention in precision machining environments due to its design flexibility and customization of the fabricating tool structure. This paper presents experimental demonstration of additively fabricated tools by SLS method in double-sided lapping process of Al2O3 ceramic samples. The experimental investigations have been carried out to evaluate the attained technological effects on ceramic samples, such as surface roughness (Sa) and material removal rate (MRR). Additionally, the wear mechanism of the lapping wheel was assessed based on global map observation using 3D laser scanner and the radial axis profile using 3D optical profilometer. The results of the first experimental study showed significant improvement in the surface quality of ceramic samples with 68.75% reduction of the initial surface roughness within 10 minutes of machining time from Sa 1.6 µm to 0.5 µm. Moreover, the enhancement of ceramics samples surface quality was attained with the removal rate of 91.2 mg/min. Furthermore, the radial axis profile of tools, surface topographies, and global map observations indicated the potential of polyamide tool by resulting in relatively lower wear conditions with the grooves formed on the tool surface. The research revealed considerable promise of SLS-printed lapping wheels in double-sided precision machining of a difficult-to-cut Al2O3 ceramics while achieving favourable technological effects and minimum wear condition.