Multiscale assessment of structured coated abrasive grits in belt finishing process

• We have studied belt finishing operations of cylindrical steel workpieces by varying the abrasive belt morphology.
• Wear and abrasive belt characterization have been studied by SEM observations.
• We have made an energetic analysis of abrasion mechanisms.
• We have introduced the multiscale analysis of grinded surfaces.
• Some guidances have been given in order to improve the functionalization of the obtained surface by belt finishing.
• Relationship between belt morphologies and workpieces surface roughness has been studied.

This paper outlines the link between grit morphology and surface roughness of belt-finished workpieces. It features a comparative analysis of a new generation of abrasive belts with diverse abrasive structures, and a multi-scale roughness characterization of abrasive belt wear on a variety of finished surfaces. The ultimate thickness of the mechanically deformed layer and surface profile projections depends, to a great extent, on the abrasive mechanisms of friction and wear employed in the finishing process. By modifying the physical mechanisms (cutting, plowing or sliding), it is possible to achieve a concomitant change in the rate of material removal and, consequently, to the specific surface roughness of the finished parts.Our research shows that the active roughness scale resulting from belt finishing is strongly dependent on the grit orientation and the binder distribution. The results are promising for increasing the efficiency of the abrasion processes and for improving the surface texturing of finished parts.