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<p>Grinding remains a critical finishing process in manufacturing, yet it is often constrained by excessive friction, thermal damage, and inefficient coolant delivery—especially when machining hard-to-grind materials like MO40 steel. This study explores the design and evaluation of five innovative grinding tools, fabricated using vat photopolymerization-based 3D printing, each featuring distinct geometric modifications to enhance grinding performance. The tested designs included: a Standard Tool (ST), a Cylindrical Cooling Channel Tool (CCT), a Venturi Cooling Tool (VCT), and two V-grooved tools (T100 and T200) tailored for improved chip evacuation and thermal regulation. Experimental assessments revealed that structured geometries significantly influence tool behavior. Among them, the T100 tool exhibited the highest grinding ratio, lowest wear rate, and finest surface finish, attributed to enhanced coolant flow and reduced thermal load. These findings demonstrate the potential of geometrically engineered, 3D-printed tools to overcome conventional grinding limitations, paving the way for more efficient and sustainable machining of advanced alloys. </p>

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Resin-Bonded Discontinuous Grinding Tools for MO40 Steel Manufactured by Vat Photopolymerization

  • 期刊论文

  • 发表日期：

    2025年6月30日

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  • Babak Houshmand,
  • Seyed Mohsen Safavi

摘要

Grinding remains a critical finishing process in manufacturing, yet it is often constrained by excessive friction, thermal damage, and inefficient coolant delivery—especially when machining hard-to-grind materials like MO40 steel. This study explores the design and evaluation of five innovative grinding tools, fabricated using vat photopolymerization-based 3D printing, each featuring distinct geometric modifications to enhance grinding performance. The tested designs included: a Standard Tool (ST), a Cylindrical Cooling Channel Tool (CCT), a Venturi Cooling Tool (VCT), and two V-grooved tools (T100 and T200) tailored for improved chip evacuation and thermal regulation. Experimental assessments revealed that structured geometries significantly influence tool behavior. Among them, the T100 tool exhibited the highest grinding ratio, lowest wear rate, and finest surface finish, attributed to enhanced coolant flow and reduced thermal load. These findings demonstrate the potential of geometrically engineered, 3D-printed tools to overcome conventional grinding limitations, paving the way for more efficient and sustainable machining of advanced alloys.