Abstract Porous metal-bonded grinding wheels with high porosity and controllable pore shape, size, quantity and distribution are in great demand but hard to realize for traditional process. In this study, the novel method is proposed to fabricate porous metal-bonded grinding wheels based on selective laser melting technology. Three kinds of grinding wheels, including octahedron structure wheel, honeycomb structure wheel and solid structure wheel, are designed and fabricated using this novel method. Additionally, morphological characterization is conducted in terms of porous structure, microstructure and bonding condition. Furthermore, grinding performance is evaluated in terms of grinding force, material removal rate, ground surface roughness and hardness. Experimental results indicate that the SLM-fabricated grinding wheels possess the excellent dressing and self-sharpening ability, good bonding strength, controllable pore structure, high porosity and good comprehensive grinding performance. Compared with electroplated wheel, better machined surface roughness and slighter work hardening can be achieved by the SLM-fabricated wheels based on the similar material removal capacity. Among the SLM-fabricated wheels, octahedron structure wheel possesses the smallest extrusion and friction force, the highest instantaneous cutting force and the slightest work hardening, and solid structure wheel possesses the largest material removal rate.

中文翻译：

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选区激光熔化（SLM）金属结合剂金刚石砂轮的设计与性能研究

摘要 具有高孔隙率和可控孔隙形状、大小、数量和分布的多孔金属结合剂砂轮的需求量很大，但传统工艺难以实现。在这项研究中，提出了一种基于选择性激光熔化技术制造多孔金属结合剂砂轮的新方法。采用这种新方法设计制造了八面体结构砂轮、蜂窝结构砂轮和实体结构砂轮三种砂轮。此外，在多孔结构、微观结构和结合条件方面进行形态表征。此外，还根据磨削力、材料去除率、磨削表面粗糙度和硬度来评估磨削性能。实验结果表明，SLM制造的砂轮具有优良的修整和自锐能力，结合强度好，孔结构可控，孔隙率高，综合磨削性能好。与电镀砂轮相比，基于相似材料去除能力的 SLM 制造砂轮可以实现更好的加工表面粗糙度和更轻微的加工硬化。在SLM制造的砂轮中，八面体结构砂轮挤压力和摩擦力最小，瞬时切削力最高，加工硬化最轻微，实心结构砂轮材料去除率最大。与电镀砂轮相比，基于相似材料去除能力的 SLM 制造砂轮可以实现更好的加工表面粗糙度和更轻微的加工硬化。在SLM制造的砂轮中，八面体结构砂轮挤压力和摩擦力最小，瞬时切削力最高，加工硬化最轻微，实心结构砂轮材料去除率最大。与电镀砂轮相比，基于相似材料去除能力的 SLM 制造砂轮可以实现更好的加工表面粗糙度和更轻微的加工硬化。在SLM制造的砂轮中，八面体结构砂轮挤压力和摩擦力最小，瞬时切削力最高，加工硬化最轻微，实心结构砂轮材料去除率最大。