Effect of process parameters on the wear characteristics and lapping performance of SLS-fabricated polyamide tools

Nowadays, additive manufacturing (AM) offers new possibilities in the production of tools for various finishing processes, such as grinding, lapping, and polishing. In this study, the effect of different lapping parameters was investigated on the wear characteristics and lapping performance of SLS printed polyamide tools. In accordance with the PS/DK 2 3 experimental design, machining of Al 2 O 3 ceramic materials have been conducted on one-sided lapping setup, in which crucial process input factors, such as unit pressure p , velocity v, and machining time t, were considered at upper (+) and lower (−) two different levels. Technological effects related to the material loss of Al 2 O 3 ceramic samples, as well as their surface quality based on 2D (Ra, Wa) and 3D (Sa, Sq) roughness and waviness parameters, were analyzed. The experimental results indicated a noticeable influence of the lapping input parameters on the analyzed machining effects, as well as on the shape profile and wear value of the polyamide lapping wheels abrasive segments. Moreover, considering the result of the statistical analysis, mathematical models are developed for the technological effects related to the values of mass material loss Δm , linear material loss Δh , and surface height parameter roughness Ra, in the form of linear regression equations. The developed mathematical models can be used to precisely predict the values of the output variables within the specified range of variation of the parametric settings. • Application of SLS-printed tools during one-sided free abrasive machining of Al 2 O 3 ceramics materials. • Effect of various lapping parameters on technological results and wear characteristics. • Evaluation of segments wear using minimum zone (MZ) techniques and maximum height (Wt) waviness parameters. • Surface quality assessment of Al 2 O 3 ceramics based on surface height parameters. • Determination of technological effects based on developed mathematical models.