TY - GEN

T1 - Production and characterisation of batch manufactured flexible micro-grinding tools for finishing metallic surfaces

AU - Steinhoff, Lukas

AU - Dencker, Folke

AU - Wurz, Marc Christopher

N1 - Funding Information: The authors would like to thank the German Research Foundation for their organizational and financial support within the project "Batchprocessed flexible micro-grinding tools for end machining of metallic surfaces" (WU 558/26-1).

PY - 2022

Y1 - 2022

N2 - In this study, we report on batch production and use of flexible micro-grinding tools for finishing metallic surfaces. By using photo-structurable polyimide as a matrix material, many similar heads of these grinding tools can be produced at once using a photolithography process. The abrasive (silicon carbide) is easily integrated into the matrix by dispersing it into the polymer before applying the polyimide-abrasive-suspension (PAS) to the substrate. By varying the process parameters of batch production and the weight fractions of PAS, the layer thickness and material properties like the Young's modulus are adjusted in order to optimize the grinding performance in a given application. After separation, the tool heads are bonded to the tool shafts. Due to the two-part construction, the heads can be easily exchanged after wear and the shafts can be reused. In addition, the diameter of the tool shafts is tuned to standardized collets. This allows the use of the grinding tools in conventional machine tools, which enables easy integration into existing manufacturing cycles. The flexibility of the micro-grinding tools allows high precision machining of metallic surfaces, which will be shown for copper. The comparison of the infeed and the material removal shows the high flexibility of the tool. The grinding is followed by a roughness analysis of the surface. Single grinding processes are compared to multi grinding processes and it is shown that multiple steps halve the surface roughness in this grinding procedure. The tool wear is measured as well. First, we observe a high initial tool wear by a dressing process and after that it reduces to under 1 µm for each further grinding step with a tool path length of 42 mm.

AB - In this study, we report on batch production and use of flexible micro-grinding tools for finishing metallic surfaces. By using photo-structurable polyimide as a matrix material, many similar heads of these grinding tools can be produced at once using a photolithography process. The abrasive (silicon carbide) is easily integrated into the matrix by dispersing it into the polymer before applying the polyimide-abrasive-suspension (PAS) to the substrate. By varying the process parameters of batch production and the weight fractions of PAS, the layer thickness and material properties like the Young's modulus are adjusted in order to optimize the grinding performance in a given application. After separation, the tool heads are bonded to the tool shafts. Due to the two-part construction, the heads can be easily exchanged after wear and the shafts can be reused. In addition, the diameter of the tool shafts is tuned to standardized collets. This allows the use of the grinding tools in conventional machine tools, which enables easy integration into existing manufacturing cycles. The flexibility of the micro-grinding tools allows high precision machining of metallic surfaces, which will be shown for copper. The comparison of the infeed and the material removal shows the high flexibility of the tool. The grinding is followed by a roughness analysis of the surface. Single grinding processes are compared to multi grinding processes and it is shown that multiple steps halve the surface roughness in this grinding procedure. The tool wear is measured as well. First, we observe a high initial tool wear by a dressing process and after that it reduces to under 1 µm for each further grinding step with a tool path length of 42 mm.

KW - high precision machining

KW - micro production technology

KW - micro-grinding

KW - Precision engineering

UR - http://www.scopus.com/inward/record.url?scp=85145587797&partnerID=8YFLogxK

M3 - Conference contribution

AN - SCOPUS:85145587797

T3 - European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022

SP - 77

EP - 80

BT - European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022

A2 - Leach, Richard K.

A2 - Akrofi-Ayesu, A.

A2 - Nisbet, C.

A2 - Phillips, Dishi

T2 - 22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

Y2 - 30 May 2022 through 3 June 2022

ER -