Polycrystalline diamond (PCD)-coated tungsten carbide (WC) is a highperformance 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.
Metal-bonded diamond wheels are widely used in high-precision grinding of hard and brittle materials; unfortunately, they are difficult to true and dress. This paper addresses this problem in that it proposes a variation on the electrical discharge dressing technique. The advantages of the proposed method are discussed and an electrode compensation model is formulated. The topography and surface profile of the diamond wheel are analysed as a function of various dressing parameters. The performance of the wheel after dressing is evaluated using experimentally measured grinding forces and surface roughness values. It is shown that the proposed method is a viable technique for the truing and dressing of diamond grinding wheels.
The technology of superabrasive grinding has been developed in order to achieve high-quality finish in extremely hard and brittle materials. Thereafter, truing and dressing technology on super abrasive grinding wheel is one of the most important subjects on precise machining field at present. In this paper, mist-jetting electrical discharge technology was applied to dressing metal-bonded superabrasive wheels. And a systematical study on the mechanism of selective removal of the bond was proposed. Experiments on dressing bronze bonded diamond grind wheels were carried out on a die-sinking electrical discharge machine. The diamond wheel topographies before and after electrical discharge dressing were observed by VH-800 3D digital microscope. The wheel profiles before and after dressing were observed. The results of electrical discharge dressing under different electrical parameters were compared. Experimental results indicate that the favorable surface topography can be obtained under suitable processing parameters and mist-jetting electrical discharge dressing (MEDD) is feasible for metal-bonded diamond grinding wheel.
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