Fabrication of Polycrystalline Diamond Wheels by Micro Wire-EDM using a Novel Pulse Generator

Yan, M-T; Fang, G-R.; Yt, Liu; Li, J-R.

doi:10.1016/j.procir.2013.03.013

Cited by 10 publications

(5 citation statements)

References 14 publications

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“…41 To further improve surface roughness, new power generators working on new principles were developed to optimize peak current and pulse duration. 80,114,[116][117][118] Non-electrical factors. The dielectric plays a critical role in improving SR.…”

Section: Surface Roughnessmentioning

confidence: 99%

“…59 The electrode materials also contribute to the thickness and distribution structure of the metamorphic layer, and structure dense electrode materials such as copper and cupronickel were more suitable for reducing the thickness of the metamorphic layer than the graphite electrode. 100,128 Using variable resistance 84 and digital signal control circuits 117,118 could reduce the thickness of the metamorphic layer by applying different discharge currents in different discharge stages. Usually, reconditioning of sintered PCD is carried out by ECM or grinding with special WC (green grit Carbide) to minimize HAZ and associated defects.…”

Section: The Defects Of Machined Surfacesmentioning

confidence: 99%

See 1 more Smart Citation

Electrical discharge machining of polycrystalline diamond: A review

Wang

Guo

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Owing to its ultra-hardness and exceptional wear resistance, polycrystalline diamond (PCD) is widely used in numerous applications such as bearing, nozzle, metal cutting, oil and gas, and hard rock mining. However, the hardness of diamond means PCD products are incredibly difficult to manufacture. Electrical discharge machining (EDM) is one of the most effective non-traditional methods used for machining PCD materials, although the unique composite structure and low electrical conductivity of PCD lead to low machining efficiency. This paper presents an overview of the methods and newly emerged state-of-the-art technologies to improve material removal rate and surface quality as well as the mechanisms behind these methods. Literature analysis shows that efficiency improvement could be achieved by increasing energy utilization and the sparking gap in EDM. The utilization of discharge energy is highly sensitive to the expansion of single discharge sparks. Further improvement in machining efficiency could be achieved by enhancing discharge expansion and explosive force through changing processing forms, dielectric, electrode shape, and power generator in the future. To provide a comprehensive insight of the machinability of PCD, EDM processes of using PCD as tool electrodes to machine other materials to improve machining performance are also discussed.

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Section: Surface Roughnessmentioning

confidence: 99%

Section: The Defects Of Machined Surfacesmentioning

confidence: 99%

Electrical discharge machining of polycrystalline diamond: A review

Wang

Guo

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…To meet the need of precision milling in fine woodworking manufacturing, circular run-out errors of six-tooth polycrystalline diamond (PCD) miller φ125 mm are commonly restricted to less than 0.080 mm. Hence, high-precision cutting tools play an important role in some standard operating procedures [3][4][5]. Furthermore, in machining-reinforced laminated flooring with Al 2 O 3 overlay, processes generally suffer from tool wear if removing relatively large volumes of material [4].…”

Section: Introductionmentioning

confidence: 99%

“…Electrical discharge machining (EDM) has been emerging as one of the most popular methods for the fabrication of PCD tools because of its excellence in providing fast, economic and precision micromachining [5]. There are basically three types of eroding process: sink erosion, wire erosion and disk/rotary erosion.…”

Section: Introductionmentioning

confidence: 99%

Edge fabrication and process optimization of precision woodworking PCD millers with disk electrical discharge machining

Zhang

et al. 2015

Int J Adv Manuf Technol

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Polycrystalline diamond (PCD) tools fulfil a vital role in the woodworking industry, with its ability to achieve smooth machining quality and long service life, along with excellent performance features. However, diamond tools' fabrication is a difficult material removal process. In this study, we propose and develop an electrical discharge machining (EDM) grinding method with disk electrode. Tool profiles are captured by a measuring probe, and path curves are tracked by a peripheral disk in edge fabrication. Experiments of graphite and copper serving as electrode are carried out, respectively, in the disk discharge grinding process. In addition, with design of experiments on PCD machining, different Disk EDM parameters are obtained to evaluate the influence of dominant factors on machining speed and surface quality. Optimal gap reference voltage, wheel rotational speed and pulse width are extracted, respectively, under the conditions of two electrode materials. Results show that pulse width plays the most important role in machining, and copper electrode can effectively produce smoother surface than graphite when used as electrode in Disk EDM. Moreover, edge fabrication of spiral miller (φ125 mm) is precisely realized with circular run-out errors less than 0.050 mm.

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“…The pulse generator using anti-electrolysis circuitry and digital signal processor based pulse control circuit was developed to suppress damages on the machined surface of PCD while achieving stable machining. By applying a specific pulse generator, a PCD wheel with a grinding-edge thickness of 3µm has been successfully fabricated by micro wire-EDM [5].…”

mentioning

confidence: 99%

Comparative Study of Electrode Wear Estimation in Wire EDM using Multiple Regression Analysis and Group Method Data Handling Technique for EN-8 and EN-19

Ugrasen¹

2014

BIJIEMS

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Wire Electrical Discharge Machining (WEDM) is a specialized thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. In WEDM a specific wire runoff speed is applied to compensate wear and avoid wire breakage. Since the workpiece generally stays stationary and short discharge durations are applied, the relative displacement between wire and workpiece during one single discharge is very small. This study outlines the development of model and its application to optimize WEDM machining parameters using the Taguchi's technique which is based on the robust design. Present study outlines the electrode wear estimation in the wire EDM. EN-8 and EN-19 was machined using different process parameters based on L' 16 orthogonal array. Among different process parameters voltage and flush rate were kept constant. Parameters such as bed speed, current, pulse-on and pulse-off was varied. Molybdenum wire having diameter of 0.18 mm was used as an electrode. Electrode wear was measured using universal measuring machine. Estimation and comparison of electrode wear was done using multiple regression analysis and group method data handling technique. From the results it was observed that, measured electrode wear and estimated electrode wear correlates well with respect to MRA than GMDH.

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Fabrication of Polycrystalline Diamond Wheels by Micro Wire-EDM using a Novel Pulse Generator

Cited by 10 publications

References 14 publications

Electrical discharge machining of polycrystalline diamond: A review

Electrical discharge machining of polycrystalline diamond: A review

Edge fabrication and process optimization of precision woodworking PCD millers with disk electrical discharge machining

Comparative Study of Electrode Wear Estimation in Wire EDM using Multiple Regression Analysis and Group Method Data Handling Technique for EN-8 and EN-19

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