3D printed compliance tool incorporated internal-impeller structure for high performance face grinding of titanium alloy

During compliant face grinding of difficult-to-machine areas like the blade runner surface, significant heat accumulation at the tight interface between the workpiece and tool. This leads to limitations in surface integrity and tool life longevity. This study introduces a novel cooling method that incorporates an axially rotating impeller into the cavity of a small compliant grinding tool. The internal impeller structured compliant tool was prepared base on additive manufacturing. Numerical simulations and experimental studies were carried out to investigate its heat transfer mechanisms and its effect on the continuous grinding performance. The findings indicate that while favorable surface roughness and high material removal rates coincide with elevated grinding temperatures, the Shore hardness of the flexible material decreases as the grinding temperature rises. Consequently, there is a reduction in grit cutting depth and an increase in the proportion of rubbing and ploughing grit due to the grit’s height rearranges. The designed internal impeller facilitates the external cooling air with internal vortices to reach the grinding interface zone limiting heat accumulation to below 91.0°C and removing chips to reduce grit adhesion. Consequently, the grinding performance was more consistent, with a stable material removal depth ranging from 97µm to 103µm. 3D-printing-based compliant tools provide new insights into consistently high grinding performance for complex parts.