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

verfasst von

Lukas Steinhoff, Folke Dencker, Marc Christopher Wurz

Abstract

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.

Organisationseinheit(en)

Institut für Mikroproduktionstechnik

Typ

Aufsatz in Konferenzband

Seiten

77-80

Anzahl der Seiten

4

Publikationsdatum

2022

Publikationsstatus

Veröffentlicht

Peer-reviewed

Ja

ASJC Scopus Sachgebiete

Wirtschaftsingenieurwesen und Fertigungstechnik, Maschinenbau, Environmental engineering, Werkstoffwissenschaften (insg.), Instrumentierung