On-machine Fabrication of Boron-doped Polycrystalline Diamond Cutting Tools by Combining Wire Electrical Discharge Machining and Abrasive Grinding

• Published in: Sensors and materials Vol. 36; no. 9; p. 3797
• Main Authors: Lin, Yue-Feng, Lai, Pei-Yu, Luo, Yuan-Xiu
• Format: Journal Article
• Language: English
• Published: Tokyo MYU Scientific Publishing Division 05.09.2024
• Subjects: Abrasive cutting machines; Abrasive cutting wheels; Abrasive machining; Abrasive wear; Boron; Chipping; Cutting equipment; Cutting tool materials; Cutting tools; Diamond machining; Diamond tools; Ductile-brittle transition; Electric discharge machining; Graphitization; Grinding tools; Grinding wheels; Manufacturing; Mechanical properties; Microcracks; Polycrystalline diamond; Polycrystals; Raman spectroscopy; Sharpening; Surface properties; Surface roughness; Wire
• ISSN: 0914-4935; 2435-0869
• DOI: 10.18494/SAM5097

A sequential technique that combines wire electrical discharge machining (wire-EDM) and abrasive grinding on dedicated equipment improves the edge quality of boron-doped polycrystalline diamond (BD-PCD) cutting tools. In this study, we focus on material removal mechanisms during BD-PCD machining and surface graphitization caused by wire-EDM thermal damage. Surface topography is used to distinguish ductile- and brittle-regime grinding in tool production. Resin-bonded diamond wheels outperform electroplated diamond wheels in abrasive grinding owing to their self-sharpening capabilities. The experimental results show that BD-PCD tools have higher mechanical properties and performance than standard PCD tools. Maximum edge chipping on BD-PCD surfaces depends on the depth of cut and grinding speed. Microgrinding experiments on BK7 glass reveal that the recommended tool manufacturing approach, which merges wire-EDM and abrasive grinding, results in high-quality surfaces free of microcracks and achieves a surface roughness of 6 nm Sa. Abrasion on the flank face and chipping on the periphery are the main wear patterns on grinding tools. In this study, we improve our understanding of BD-PCD microcutter production, focusing on parameter management for optimal surface quality, edge integrity, and tool performance. We emphasize the necessity of choosing the right grinding wheel to achieve the necessary surface and subsurface quality when making microcutting tools. Raman spectroscopy results are used to explain thermal deterioration when diamond grains turn into graphite at high manufacturing temperatures. We address the challenges of producing high-quality microcutting tools and offer insights into improving BD-PCD tool performance and edge quality.