Measurements of the active surface microgeometry of the grinding wheel by contact and optical methods are commonly used to obtain a cloud of points representing the surface of the examined tool. Parameters that can be determined on the basis of the above-mentioned measurements can be universal parameters, which are commonly used to assess the geometric structure of a surface or parameters taking into account specific properties of the grinding wheel active surface (GWAS) structure. This article proposes a methodology for determining the average level of binder, which allows the definition the cut-off level required to separate from the measurement data: (i) the areas representing grains, (ii) the areas of gumming up of the grinding wheel, and (iii) deep cavities in approximately the same places on the investigated grinding wheel, regardless of the degree of its wear. This, in turn, allows one to track changes in characteristic parameters computed from measurements of texture in the above-mentioned areas due to different GWAS wear processes. The research was based on the analysis of data obtained from measurements of single-layer grinding wheels using the replica technique. The adopted measurement methodology enables measurement of approximately the same (94% coverage) areas of the GWAS at four stages of grinding wheel operation. Errors that were computed related to the determination of the volume of abrasive on the GWAS at various stages of wear using the developed methodology were lower, on average, by 48% compared to the automatic recognition of islands made with a commercial software.

During the operation of a single-layer grinding wheel (SLGW), irreversible changes occur on its active surface due to wear. The study of grinding-wheel microgeometry changes can be based on the measurement of the surface texture as well as the determination and analysis of its parameters. The article deals with the selection of suitable texture parameters and an appropriate mathematical model carrying information about the SLGW condition. In the study, samples of Pyrowear 53 steel were ground using electroplated cBN single-layer grinding wheels until they were completely worn out or removed assumed volume of the workpiece material. Each SLGW worked with constant process parameters. Among the 144 parameters tested, the highest sensitivity to changes in wheel active surfaces caused by wear was shown by the mean value of the mean island heights Zmean_m. In-depth research was conducted for Zmean_m and reduced peak height Spk. Compared to Spk, Zmean_m has proven to be a better measure of wear, especially when large areas of sticking occur. Moreover, the second-degree models linking Zmean_m and Spk to the process parameters and the specific material loss were better suited to the empirical data than the exponential models.

The article presents the results of experimental studies of the milling process of Vanadis 4 Extra - tool steel 1.2210 with a four-flute AlCrN-coated end mill. On the basis of the measured values of the total cutting force F and the roughness parameters Ra and Rz of machined surfaces, the...

Material Extrusion (MEX) additive manufacturing (AM) of ABS polymer components often requires post-process machining to achieve the necessary dimensional precision and surface quality. However, the influence of printing parameters and tool–material interaction in hybrid manufacturing remains insufficiently explored. This study investigates the impact of initial hole size (D_start), build orientation, and cutting parameters (cutting speed and feed rate) on the dimensional accuracy and surface roughness of machined holes in ABS-M30 specimens. Samples were fabricated in vertical and horizontal orientations and subjected to drilling in solid material and enlargement of printed pilot holes using a twist drill on a 5-axis machining center. Dimensional deviation and surface roughness (Ra, Rz) were evaluated using coordinate metrology and profilometry. The results showed that the smallest machining allowance (0.062 mm per side) was insufficient to completely remove the printing-induced surface texture, resulting in significantly higher and more variable Ra and Rz values. This distinct low-machining-allowance regime was confirmed by statistical analysis and representative optical observations. Conversely, a machining allowance of 0.565 mm per side (corresponding to D_start = 9 mm) resulted in substantially lower surface roughness (Ra ≈ 1.6 µm). Vertical build orientation generally provided better surface quality than the horizontal orientation, which was consistent with fewer visible surface features in the selected optical fields of view. All machining conditions resulted in negative dimensional deviations, indicating elastic recovery of the ABS material after machining. An exploratory multi-response ranking showed that the lowest composite quality scores for overall final hole quality were associated with D_start = 10 mm (machining allowance of 0.062 mm per side). When the analysis was limited to the machining-dominated regime, the lowest score was obtained for the vertical build orientation, D_start = 9 mm, a cutting speed of 40 m/min, and a feed rate of 0.2 mm/rev. These findings provide preliminary guidelines for selecting hybrid manufacturing conditions for MEX-manufactured ABS-M30 components.