A Comparative Study of Precision Surface Grinding Using Additively Fabricated Acrylonitrile–Butadiene–Styrene (ABS) Wheels with Continuous and Serrated Working Surfaces

Nowadays, high requirements imposed by mechanical components make it necessary to develop modern production methods. Additive technologies have been dynamically developing in recent years, showing many advantages associated with the fabrication of elements with complex geometries and structures. One of the areas where the potential of additive technologies is exploited is the rapid tooling sector, which is based on the rapid production of tools and components used in various manufacturing methods. Currently, apart from industrial additive fabrication using metal and plastic powders, desktop and low-cost devices for additive manufacturing are gaining more and more importance in the production of functional elements. This paper presents the experimental results obtained from testing the micro-abrasive acrylonitrile-butadiene-styrene ABS tools fabricated by fused filament fabrication (FFF) technology and reinforced with SD 28/20 diamond grains uniformly distributed on the working surface of the tools after they were made. Precision surface grinding operations of 41Cr4 alloy steel were carried out on a portable five-axis CNC milling machine using wheels with continuous and serrated working surfaces. The tool with a serrated working surface enabled a more efficient material removal and produced a better surface finish. In particular, a low wear rate of both FFF-printed tools was confirmed after all experiments. Promising results were obtained, showing the potential for a wider industrial application of the tested tools.