Sage Journals: Discover world-class research

Abstract

Polycrystalline diamond (PCD)-coated tungsten carbide (WC) is a high-performance cutting tool material widely used in industry for cutting or ultra-precision cutting of advanced engineering materials, but it is difficult to machine using conventional machining techniques owing to its high hardness. However, wire electrical discharge machining (wire EDM) offers advantages in machining PCD-coated WC in terms of process reliability and flexibility to machine different shapes. To relieve pollution issues associated with traditional wet wire EDM, the present study investigated the feasibility of near-dry wire EDM of PCD-coated WC cutting tool material using deionized water and air mist. A parametric study on spark cycle and spark duration was carried out, and the effect of these two important wire EDM process parameters on machining performance in terms of material removal rate (MRR) and surface roughness (R_a) was analysed. Compared with conventional wet wire EDM, near-dry wire EDM consistently produces better R_a values on the PCD-coated WC workpiece, but near-dry wire EDM produces lower MRR than wet wire EDM under some conditions.

Keywords

near-dry machining wire electrodischarge machining PCD-coated WC material removal rate surface roughness

References

Ding

Liew

W. Y. H.

Liu

X. D.

, ‘Evaluation of machining performance of MMC with PCBN and PCD tools’ J. Wear 259 (7–12) (2005): 1225–1234.

Durante

Rutelli

Rabezzana

, ‘Aluminum-based MMC machining with diamond-coated cutting tools’ J. Surf. Coat. Technol. 94–95 (1–3) (1997): 632–640.

Y. F.

J. H.

Yang

Luo

S. B.

Y. C.

, ‘Workpiece surface quality when ultra-precision turning of SiC_p/Al composites’ J. Mater. Process. Technol. 203 (1–3) (2008): 166–175.

Wang

Z. G.

Z. J.

Cheng

Y. N.

Ning

S. Y.

, ‘Analysis and design of PCD milling tool for machining copper alloy materials’ Int. J. Comput. Applic. Technol. 28 (1) (2007): 110–115.

Nurul Amin

A. K. M.

Ismail

A. F.

Nor Khairusshima

M. K.

, ‘Effectiveness of uncoated WC—Co and PCD inserts in end milling of titanium alloy Ti–6Al–4V’ J. Mater. Process. Technol. 192–193 (1–7) (2007): 147–158.

Reis

D. D.

Abrão

A. M.

, ‘The machining of aluminium alloy 6351’ Proc. IMechE, Part B: J. Engineering Manufacture 219 (B1) (2005): 27–33 DOI: 10.1243/095440505X7966.

Philbin

Gordon

, ‘Characterisation of the wear behaviour of polycrystalline diamond (PCD) tools when machining wood-based composites’ J. Mater. Process. Technol. 162–163 (Spec. lss.) (2005): 665–672.

Tanimura

Isuzugawa

Fujita

Iwamoto

Kamitani

, ‘Development of EDM in the mist’ (1989).

Kunieda

Yoshida

, ‘Electrical discharge machining in gas’ Ann. CIRP 46 (1) (1997): 143–146.

10.

Kunieda

Furudate

, ‘High precision finish cutting by dry WEDM’ Ann. CIRP—Mfg Technol. 50 (1) (2001): 121–124.

11.

Kao

C. C.

Tao

Lee

S. W.

Shih

A. J.

, ‘Dry wire electrical discharge machining of thin workpiece’ Trans. NAMRI/SME 34 (2006): 253–260.

12.

Kao

C. C.

Tao

Shih

A. J.

, ‘Near dry electrical discharge machining’ Int. J. Machine Tools Mf. 47 (15) (2007): 2273–2281.

13.

Pretorius

Howard

T. P.

Bowler

J. J.

Toomey

, ‘Performance and processability of PCD cutting tool materials’ J. Ind. Diamond Rev. 66 (4) (2006): 53–57.

14.

Spur

Appel

, ‘Wire EDM cutting of PCD’ J. Ind. Diamond Rev. 57 (575) (1997): 124–130.

15.

Spur

Puttrus

Wunsch

U. W.

, ‘Wire EDM of PCD’ J. Ind. Diamond Rev. 48 (529) (1988): 264–266.

16.

Miller

S. F.

Kao

C. C.

Shih

A. J.

, ‘Investigation of wire electrical discharge machining of thin cross-sections and compliant mechanisms’ Int. J. Machine Tools Mf. 45 (15) (2005): 1717–1725.

17.

Miller

S. F.

Shih

A. J.

, ‘Investigation of the spark cycle on material removal rate in wire electrical discharge machining of advanced materials’ Int. J. Machine Tools Mf. 44 (4) (2004): 391–400.

Parametric study on near-dry wire electrodischarge machining of polycrystalline diamond-coated tungsten carbide material

Abstract

Abstract

Keywords

References