WEDM condition parameter optimization for PCD microtool geometry fabrication process and quality improvement

摘要

To increase fabrication efficiency for poly-crystalline diamond (PCD) microtools, wire EDM technology was applied and optimized by using a design of experimentation. For roughing, the productivity must be maximized while for finishing, the surface roughness must be minimized to achieve the best overall quality. Using three different grades of PCD, experimental results show a significant increase in productivity with no significant decrease in microtool quality, which was confirmed by hexagonal end-mill fabrication using both non-optimized and optimized conditions.