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<p>This study investigates the optimization of grinding MO40 alloy steel using engineered abrasive tools fabricated via vat photopolymerization from a novel SiC-reinforced urethane acrylate resin. To overcome the limitations of conventional grinding, such as excessive heat and tool wear, various tool geometries, including a Standard Tool (ST) and a Cylindrical Coolant-channel Tool (CCT), were systematically evaluated under a full factorial experimental design by varying depth of cut and feed rate. Key performance metrics like cutting forces, temperature, tool wear, and surface roughness were analyzed using a Multi-Criteria Decision-Making (MCDM) approach to identify optimal parameters. Results indicate that the ST performed best at a low depth of cut (40&#xa0;µm) and high feed rate (1000&#xa0;mm/min), achieving a surface roughness of 0.081&#xa0;µm and minimal wear by activating the SiC grains’ self-sharpening mechanism. In contrast, the CCT excelled under aggressive conditions (120&#xa0;µm depth of cut, 1000&#xa0;mm/min feed rate) due to its internal cooling channels facilitating superior thermal management and chip evacuation. This research validates additive manufacturing as a powerful method for creating application-specific abrasive tools with tailored geometries that enhance grinding efficiency for high-strength steels.</p>

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Optimization of grinding processes for MO40 alloy steel using additively manufactured, engineered abrasive tools

  • 期刊论文

  • 发表日期：

    2026年6月29日

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  • Babak Houshmand,
  • Seyed Mohsen Safavi

摘要

This study investigates the optimization of grinding MO40 alloy steel using engineered abrasive tools fabricated via vat photopolymerization from a novel SiC-reinforced urethane acrylate resin. To overcome the limitations of conventional grinding, such as excessive heat and tool wear, various tool geometries, including a Standard Tool (ST) and a Cylindrical Coolant-channel Tool (CCT), were systematically evaluated under a full factorial experimental design by varying depth of cut and feed rate. Key performance metrics like cutting forces, temperature, tool wear, and surface roughness were analyzed using a Multi-Criteria Decision-Making (MCDM) approach to identify optimal parameters. Results indicate that the ST performed best at a low depth of cut (40 µm) and high feed rate (1000 mm/min), achieving a surface roughness of 0.081 µm and minimal wear by activating the SiC grains’ self-sharpening mechanism. In contrast, the CCT excelled under aggressive conditions (120 µm depth of cut, 1000 mm/min feed rate) due to its internal cooling channels facilitating superior thermal management and chip evacuation. This research validates additive manufacturing as a powerful method for creating application-specific abrasive tools with tailored geometries that enhance grinding efficiency for high-strength steels.