Professional Documents
Culture Documents
Corresponding author.
E-mail addresses: yourwangdan@126.com, dwang@sjtu.edu.cn (D. Wang),
zws@sjtu.edu.com (W.S. Zhao), lgu@sjtu.edu.cn (L. Gu), xmkang@sjtu.edu.cn
(X.M. Kang).
wear and low productivity caused by the low electrical conduc-
tivity of PCDs. Combinations of EDM and some other methods
can improve the machining performance. The electrical discharge
grinding process offers a lower cost alternative with inherent
higher accuracy for surface shaping of PCD blanks. Cao and Zhang
(2004) developed a neural network model for an increased explo-
sive electrical discharge grinding process and in their study the
machining performance was improved with the material removal
rate increasedto9.75mm
3
/minandthe depthof diamondtungsten
carbide (WC) interface reduced to 0.03mm. Electrical discharge
milling proposed by Liu et al. (1997) is able to effectively machine
a large surface area on a PCD, where a DC source is employed
and a water-based emulsion is used as the machining uid. Laser
machining is suitable for fabrication of conventional dimension
structures for PCD tools. The laser machining of PCDs conducted
by Harrison and Henry (2006) was rened empirically to improve
cutting edge qualities, reduce surface dross and create com-
plex shapes whilst still achieving a comparatively high cutting
velocity.
When the machining size is less than 1mm, the com-
monly used machining methods are laser micro-machining and
micro-electrical discharge machining (Micro-EDM). Laser micro-
machining, besides the high cost, causes localized fusing of
material, consequently making the holes lose their cylindricity
as reported by Kaminski and Capuano (2003). Hashikawa (2004)
drilled a 100m through-hole on a PCD with laser micro-
machining rst, and then nished with EDM.
0924-0136/$ see front matter 2010 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2010.07.034
4 D. Wang et al. / Journal of Materials Processing Technology 211 (2011) 311
Table 1
Erosion resistance index of different materials.
Material Erosion resistance index (10
12
J
2
/(ms kg))
Tungsten 2.99
a
Copper 2.79
a
Steel 0.230
a
PCD About 4
a
These values are reported by Reynaerts et al. (1997).
Micro-EDM has been successfully utilized to fabricate PCD
micro-tools for machining hard and brittle materials due to its low
cost and high machining precision. Wada et al. (2002) shaped a
PCD into a 95m tool by EDM and demonstrated the effective-
ness in machining tungsten carbide, electroless plated nickel and
silicon. Morgan et al. (2004) shaped 50m PCD tools by EDM for
machining brittle glass materials.
With small discharge energy, micro-EDM can remove mate-
rials with small volumes (0.05500m
3
) accurately, which can
achieve high machining precision of micro-holes with a high thick-
ness/diameter ratioona PCD. Sheuet al. (2007) machineda 40m
PCD micro-hole with micro-EDM.
In this study, investigations were conducted to study the
impacts of the machining polarity and the micro-EDM param-
eters on machining. The inuences of the adhesion around the
tool electrode on machining performance under different machin-
ing polarities and micro-EDMparameters were discussed. Besides,
the range of desirable machining conditions including nominal
capacitances and electrode rotation speeds were searched for high
material removal rate(MRR) andlowrelativetool wear ratio(TWR).
Finally, an optimal set of machining conditions was chosen to drill
a high quality through-hole on a PCD.
The rest of this paper is organizedas follows: Section2 discusses
the relationship between micro-EDM performance and physical
properties of a PCD. Section 3 introduces the experimental equip-
ment and methods. Experimental results are given in Section 4,
followedbya discussioninSection5. Aexemplarymachiningis car-
ried out in Section 6 and nally the conclusion is given in Section 7.
2. Relationship between micro-EDM performance and
physical properties of a PCD
EDMis a thermoelectric process inwhichmaterials are removed
from a workpiece by a series of discrete sparks between the
workpiece and the tool electrode immersed in a liquid dielectric
medium. Conductivity and erosion resistance index (ERI) of PCDs
are found to be the two major factors affecting the performance of
micro-EDM.
Althoughthe diamondparticles ina PCDare not electrically con-
ductive, themetallic powder of cobalt or nickel llingtheinterstices
of the diamond particles forms an electrically conductive network,
which provides sufcient conductivity for the occurrence of an
electro-discharge machining process.
The erosion resistance index, used to indicate how suitable a
material can be machined by EDM, can be calculated by (Reynaerts
et al., 1997)
C
m
= cT
2
m
(1)
where C
m
, expressed in 10
12
J
2
/(ms kg), is the erosion resistance
index; , expressed in W/(mK), is the thermal conductivity; c,
expressed in J/(kgK), is the specic heat; and T
m
, expressed in K,
is the melting point.
In EDM, materials with high erosion resistance indices are usu-
ally difcult to be machined, resulting inlowmachining speeds and
high electrode wear. The ERI of PCDlisted in Table 1 is calculated by
Eq. (1) withthe properties listedinTable 2. The specic heat of PCDs
Table 2
Properties of the workpiece material.
Material Polycrystalline diamond
Composition (wt%) C, 5%Co
Grain size (m) 2
Thermal conductivity (W/(mK)) 540
a
Melting point (
C) 3700
b
a
This value is reported by Harrison and Henry (2006).
b
This value is reported by Cao et al. (2009).
is dependant on the types of PCDs. Since the content of diamond
is above 90% in most types of PCDs, the specic heat of diamond,
which is 0.51210
3
J/(kgK) at 20
C) 3400
Electrical resistance (cm) 5
surface shapes of the tool electrodes after machining, the material
removal rate and the relative tool wear ratio were investigated.
Each experiment was repeated three times and their results were
averaged to improve reliability.
The electrode dressing is necessary because the tool electrode is
wornout andis coveredbytheadhesioncomposedof heat-resolved
carbon and graphite after every micro-hole machining. Therefore,
the electrode dressing was carried out after each micro-hole EDM.
In this dressing process, the electrode was dressed by a sacricial
block of silvertungsten alloys, and the dressed electrode was then
used as the positive polarity and the sacricial block was used as
the negative polarity.
Material removal rate (MRR), expressed in mm
3
/min, is dened
as the ratio of the average volume of the material removed to the
machining time. Relative tool wear ratio (TWR), expressed in %, is
calculated by
TWR =
L
w
D
m
100 % (3)
where L
w
is the change in the length of the tool electrode in each
machining, and D
m
is the depth of the micro-hole in each machin-
ing. The L
w
was measured after each machining.
In order to obtain the images of the micro-holes for checking
the surface quality, a scanning electron microscope (SEM) (JSM-
6460, JEOL Ltd.) was used. A confocal Raman microscope (Raman)
(LabRam-1B, JOBIN-YVON) was also used to analyze the surface
property changes of the electrode material after a micro-EDMpro-
Table 4
Machining conditions for micro-hole machining on PCD by micro-EDM.
Experimental conditions Value/property
Pulse generator type RC
Polarity Positive polarity, negative polarity
Voltage of pulsed power (U)/(V) 106
Nominal capacitance (Cn)/(pF) 1500, 5700, 7200, 11,000, 15,200
Electrode rotation speed (n)/(rpm) 1000, 3000, 5000, 7000, 9000
Peak current (Ap)/(mA) 320
Resistance (R)/(k) Fixed to 1.2
cess. The changes of the electrode shapes during the micro-EDM
process were monitored using an online vision system.
4. Experiment results
4.1. Polarity experiments
Machining polarity has a great impact on the performance of
micro-EDM. In this study, the proper polarity of the micro-EDMfor
PCDs was chosen by comparing the tool wear length during the
micro-hole machining by feeding the tool electrode a distance of
300m against the PCD under different polarity machining condi-
tions. Fig. 2 shows the tool wear length after positive and negative
polarity machining. It can be found from Fig. 2 that the tool elec-
trode wear length is more than 240m in the positive polarity
machining where the workpiece is used as the anode and the elec-
trodeas thecathode. Bycontrast, inthenegativepolaritymachining
where the workpiece is used as the cathode and the electrode as
the anode, the tool wear length is less than 120m, which is about
half of the value in the positive polarity machining. The negative
polarity machining is, therefore, more favorable in micro-EDM for
PCDs. Hence, the following experiments in this paper were carried
out in negative polarity machining.
In addition, the electrodes before and after different polarity
machining have been measured by the SEM as shown in Fig. 3.
Compared with the tool electrode with a diameter of 110m
before machining as shown in Fig. 3(a), the electrode after negative
polarity machining is adhered with a large volume of adhesion as
shown in Fig. 3(b). By contrast, Fig. 3(c) shows an electrode after
micro-EDM on the PCD in positive polarity machining, and it can
be seen that there are little volume of adhesion on the forepart of
the electrode.
In order to analyze the composition of the adhesion on the elec-
trode produced during the machining, points A and B on the same
electrode as shown in parts (a) and (b) of Fig. 3 were measured by
Raman spectroscopy and the results of spectroscopy are shown in
Fig. 4. Raman spectroscopy is commonly used in studying changes
in chemical bonding since it can identify the chemical bonds and
symmetry of molecules. For instance, Raman spectroscopy was
used to probe the microstructure of diamond lms by Bennett et
al. (2004).
In Fig. 4, curve (B) has a band centered at 1334cm
1
denoting
amorphous carbon (a mixture of sp2- and sp3-bonded carbon),and
Fig. 2. Tool electrode wear length vs. machining polarity (other machining condi-
tions: U=106V, R=1.2k, Ap =320mA.).
6 D. Wang et al. / Journal of Materials Processing Technology 211 (2011) 311
Fig. 3. SEM images of the electrode before and after different polarity machining.(a) The electrode before micro-EDM. (b) The electrode after micro-EDM of PCD in negative
polarity machining. (The forepart of the electrode is adhered with a large volume of adhesion.) (c) The electrode after micro-EDMof PCDin positive polarity machining. (Little
volume of adhesion is adhered on the top of the electrode.)
Fig. 4. The comparison of the Raman spectra of the tool electrode before and after
negative polarity machining.
two bands centered at 1580cm
1
and 1597cm
1
both denoting
graphite as illustratedbythe arrows inFig. 4, respectively. The simi-
lar bands, however, cannot be foundincurve (A). The bands incurve
(B) indicate the existence of amorphous carbon and graphite on the
electrode after machining while curve (A) indicates that there is no
amorphous carbon and graphite on the electrode before machin-
ing. This indicates that the adhesiononthe tool electrode, produced
during the negative polarity machining, is a mixture of amorphous
carbon and graphite.
4.2. Characteristics of micro-EDM in negative polarity machining
In order to nd the inuences of the electrode rotation speed (n)
and the nominal capacitance (C
n
) on the machining performance,
a series of experiments were carried out by negative polarity
machining under various electrode rotation speeds and nominal
capacitances as shown in Table 4.
4.2.1. Quality of the micro-holes
Fig. 5 shows the SEMimages of the entrances of the micro-holes
obtained at different nominal capacitances of 1500pF, 5700pF
and 11,000pF as well as different electrode rotation speeds from
D. Wang et al. / Journal of Materials Processing Technology 211 (2011) 311 7
Fig. 5. SEM images of the entrance of the micro-holes obtained by micro-EDM. The diameters of the micro-holes machined at the nominal capacitance of 1500pF are much
larger than those machined at other nominal capacitances: (a) at 1500pF and 3000 rpm, (b) at 1500pF and 5000 rpm, (c) at 1500pF and 7000 rpm, (d) at 1500pF and 9000
rpm, (e) at 5700pF and 3000 rpm, (f) at 5700pF and 5000 rpm, (g) at 5700pF and 7000 rpm, (h) at 5700pF and 9000 rpm, (i) at 11,000pF and 3000 rpm, (j) at 11,000pF and
5000 rpm, (k) at 11,000pF and 7000 rpm and (l) at 11,000pF and 9000 rpm.
3000rpmto 9000rpm. It can be observed fromFig. 5 that the aver-
age diameter of the micro-holes is approximately 130m, while
the micro-holes, machined at the nominal capacitance of 1500pF
and the electrode rotation speed of 3000rpm, have a maximum
diameter of about 200m. Moreover, although the diameters of
the micro-holes machined at the nominal capacitance of 1500pF
decline slightly with the increase of the electrode rotation speed,
the diameters of these micro-holes are still much larger than
those machined at other nominal capacitances and result in higher
machining geometrical errors. Therefore, the nominal capacitance
should be larger than 1500pF for high machining precision.
4.2.2. Adhesion on tool electrodes after machining
The photos in Fig. 6, which were obtained by the online vision
system, show the tool electrodes after micro-EDM at different
nominal capacitances of 1500pF, 5700pF and 11,000pF as well as
different electrode rotation speeds from 3000rpm to 9000rpm. It
can be seen that there is some adhesion sticking to the electrodes
after machining and the volumes of the adhesion on the electrodes
in Fig. 6(a) through Fig. 6(d) are much larger than those in parts (e)
through (l) of Fig. 6.
4.2.3. Impacts of electrode rotation speed and nominal
capacitance on MRR
The inuences of the electrode rotation speed and nominal
capacitance onMRRwiththe electrode rotationspeedranging from
1000rpm to 9000rpm and the nominal capacitance ranging from
1500pF to 15,200pF are shown in Fig. 7. It can be found that with
theincreaseof theelectroderotationspeed, thecurves of MRRshow
a general upward trend until reaching a maximumat the electrode
rotation speed of 7000rpm and then decrease afterwards. Mean-
while, Fig. 7presents that the curves of MRRshowa general upward
trendwiththe increase of the nominal capacitance, withone excep-
tion where the MRRs at the nominal capacitance of 15,200pF are
lower thanthevalueat 11,000pFwhentheelectroderotationspeed
is above 5000rpm.
4.2.4. Impacts of electrode rotation speed and nominal
capacitance on TWR
The inuences of the electrode rotation speed and nominal
capacitance onTWRwiththe electrode rotationspeedrangingfrom
1000rpm to 9000rpm and the nominal capacitance ranging from
1500pF to 15,200pF are shown in Fig. 8. It is noted that the TWR
declines to a minimum along with the electrode rotation speed up
to 7000rpm and then rises slightly with the increase of the elec-
trode rotation speed. It is also noticed from the curves at various
nominal capacitance from top to bottom in Fig. 8 that the TWR
decreases as the nominal capacitance increases, and the rate of
decline, however, slows down when the nominal capacitance is
more than 7200pF.
5. Discussion
This sectionrst discusses the inuences of the adhesionaround
the tool electrode on the machining performances under different
8 D. Wang et al. / Journal of Materials Processing Technology 211 (2011) 311
Fig. 6. Tool electrodes after micro-EDM on PCD. The volumes of the adhesion on the electrodes in Fig. 6(a) through Fig. 6(d) are much larger than those in parts (e) through
(l) of Fig. 6: (a) at 1500pF and 3000 rpm, (b) at 1500pF and 5000 rpm, (c) at 1500pF and 7000 rpm, (d) at 1500pF and 9000 rpm, (e) at 5700pF and 3000 rpm, (f) at 5700pF
and 5000 rpm, (g) at 5700pF and 7000 rpm, (h) at 5700pF and 9000 rpm, (i) at 11,000pF and 3000 rpm, (j) at 11,000pF and 5000 rpm, (k) at 11,000pF and 7000 rpm and (l)
at 11,000pF and 9000 rpm.
Fig. 7. MRR vs. electrode rotation speed and nominal capacitance.
machining polarities and micro-EDM parameters, then the inu-
ences of micro-EDM parameters on MRR and TWR, and nally the
choice of the optimal machining conditions.
5.1. Inuence of the adhesion on machining performances under
different machining polarities
Referring to Section 4.1, where the content of the adhesion is
analyzed by Raman spectroscopy, the adhesion on a tool electrode
during machining is mainly produced from two sources. Firstly, a
large volume of graphite in the adhesion is converted fromthe dia-
monds in a PCD owing to a high energy density and a very high
temperature (up to 10,000