A feasibility study on selective laser sintering-fabricated polyamide tools in double-sided precision machining of technical aluminum oxide ceramics

The significance of the lapping process lies in its ability to achieve precise surface quality and dimensional accuracy on the workpiece.Apart from multiple controlled and uncontrolled process factors, the lapping tool type and its characteristics play a critical role in the process efficiency.Additive manufacturing (AM) recently attracted considerable attention in precision machining environments due to its design flexibility and customization of the fabricating tool structure.This paper presents an experimental demonstration of additively fabricated tools by the SLS method in the double-sided lapping process of Al 2 O 3 ceramic samples.The experimental investigations have been carried out to evaluate the attained technological effects on ceramic samples, such as surface roughness (Sa) and material removal rate (MRR).Additionally, the wear mechanism of the lapping wheel was assessed based on global map observation using a 3D laser scanner and the radial axis profile using a 3D optical profilometer.The results of the first experimental study showed significant improvement in the surface quality of ceramic samples with 68.75% reduction of the initial surface roughness within 10 minutes of machining time from Sa 1.6 µm to 0.5 µm.Moreover, the enhancement of the surface quality of ceramics samples was attained with the removal rate of 91.2 mg/min.Furthermore, the radial axis profile of tools, surface topographies, and global map observations indicated the potential of the polyamide tool by resulting in relatively lower wear conditions with the grooves formed on the tool surface.The research revealed considerable promise of SLS-printed lapping wheels in double-sided precision machining of a difficult-to-cut Al 2 O 3 ceramics while achieving favourable technological effects and minimum wear condition.