Influence of the three-body abrasion kinematics on the surface characteristics of an SLS-fabricated tool during machining of ceramics

Abstract

Abstract Experimental and modeling assessments have been conducted on the surface characteristics of SLS-printed polyamide lapping tools, considering the influence of three-body abrasion kinematics during machining of Al2O3 ceramic materials. Based on the radial axis profile and topography of segments, surface characteristics were assessed using 3D optical profilometers and minimum zone (MZ) techniques. Machining with counter-rotational kinematics exhibited larger surface shape error, resulting in an average maximum height (Wt) of 163.48 µm and pinpointing intense wear at a tool radius of 95 mm. Conversely, the highest wear with co-rotational kinematics resulted at a tool radius of 85 mm. Ceramic materials were improved by 64.74%, enhancing the initial spatial roughness Sa 1.73 µm to Sa 0.61 µm and resulting in near-zero skewness (Ssk) of surface height distribution with co-rotational kinematics. The three-body abrasion with counter-rotational kinematics resulted in 17.14% higher material removal than co-rotational kinematics. The tool-workpiece contact has been modeled considering the influence of the workpiece’s velocity and tangential acceleration along the active surface, and the findings confirmed experimental observations.