Influence of diamond particle size on the mechanical and tribological characteristics of vat photopolymerization-additive manufactured diamond tools with special structure designs

IF 7.7 2区材料科学 Q1 MATERIALS SCIENCE, COMPOSITES

Composites Communications Pub Date : 2025-08-25 DOI:10.1016/j.coco.2025.102568

Wenxin Yang , Xiaonan Ni , Zijian Hu , Xin Deng , Shanghua Wu , Jinyang Liu

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引用次数: 0

Abstract

Additive manufacturing (AM) holds significant promise for fabricating structural diamond tools capable of machining hard-brittle ceramics. However, research on stereolithography-based AM for diamond tools, particularly concerning the effects of diamond particle size and grinding tool structural topology, remains limited. These critical parameters profoundly influence the performance of diamond-reinforced composite grinding tools. The current knowledge gap in these areas constrains the advancement of AM for diamond tool production.

In this study, the effect of diamond particle size on the stability, rheological properties, and curing behavior of diamond slurry have been systematically investigated for digital light processing (DLP)-based vat photopolymerization (VPP) technology. Then, a series of novel ultraviolet-curable resin matrix diamond tools with special structure designs have been developed utilizing VPP process. The study reveals that while increasing diamond particle size can reduce viscosity and lead to better cure property of diamond slurry during VPP process, it also leads to a poor diamond dispersion stability and results in serious sedimentation of the diamond slurry. Characterization of the mechanical and thermal properties indicates that VPP processed diamond composite with 17.6 μm diamond particles (W20) exhibits a superior flexural strength, wear resistance, and thermomechanical properties. Furthermore, different structured diamond tools with W20 diamond were VPP processed and the grinding tests were conducted to Al₂O₃ workpiece. Diamond tools with groove or internal pore structures, unlike traditional solid - structured ones, deliver superior grinding performance. This stems from their superior cooling and debris - removal capabilities.

Our results strongly support the feasibility of VPP technology in fabricating diamond tools with varied diamond particle sizes and advanced porous structure designs.

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金刚石粒度对特殊结构设计的还原光聚合-添加剂制造金刚石工具力学和摩擦学特性的影响

增材制造（AM）在制造能够加工硬脆陶瓷的结构金刚石工具方面具有重要的前景。然而，基于立体光刻的金刚石工具增材制造的研究，特别是关于金刚石粒度和磨削工具结构拓扑的影响，仍然有限。这些关键参数对金刚石增强复合材料磨具的性能有着深远的影响。目前在这些领域的知识差距限制了金刚石工具生产增材制造的进步。在这项研究中，系统地研究了金刚石粒度对金刚石浆料稳定性、流变性能和固化行为的影响，用于基于数字光处理（DLP）的还原光聚合（VPP）技术。然后，利用VPP工艺开发了一系列具有特殊结构设计的新型紫外固化树脂基金刚石工具。研究表明，在VPP工艺中，增大金刚石粒度可以降低粘度，提高金刚石料浆的固化性能，但也会导致金刚石分散稳定性差，导致金刚石料浆沉降严重。力学和热性能表征表明，17.6 μm金刚石颗粒（W20）的VPP加工金刚石复合材料具有优异的抗弯强度、耐磨性和热力学性能。采用W20金刚石对不同结构的金刚石刀具进行了VPP加工，并对Al2O3工件进行了磨削试验。与传统的固体结构金刚石工具不同，具有沟槽或内部孔隙结构的金刚石工具具有优越的磨削性能。这源于其优越的冷却和碎片清除能力。我们的研究结果有力地支持了VPP技术在制造具有不同金刚石粒度和先进多孔结构设计的金刚石工具方面的可行性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Composites Communications Materials Science-Ceramics and Composites

CiteScore

12.10

自引率

10.00%

发文量

340

审稿时长

36 days

期刊介绍： Composites Communications (Compos. Commun.) is a peer-reviewed journal publishing short communications and letters on the latest advances in composites science and technology. With a rapid review and publication process, its goal is to disseminate new knowledge promptly within the composites community. The journal welcomes manuscripts presenting creative concepts and new findings in design, state-of-the-art approaches in processing, synthesis, characterization, and mechanics modeling. In addition to traditional fiber-/particulate-reinforced engineering composites, it encourages submissions on composites with exceptional physical, mechanical, and fracture properties, as well as those with unique functions and significant application potential. This includes biomimetic and bio-inspired composites for biomedical applications, functional nano-composites for thermal management and energy applications, and composites designed for extreme service environments.