Research on WEDM Process Optimization for PCD Micro Milling Tool

An initial study on WEDM process optimization for PCD micro milling tool has been carried out. With a orthogonal design of roughing and finishing condition experiment of PCD, a largest difference of WEDM parameter is obtained to calculate the influence of those parameter on cutting speed for roughing operation and surface roughness Ra and metamorphic layer thickness for finishing operation. For roughing operation, peak current and voltage pulse width are the dominant WEDM parameters; while for finishing operation, Peak current, peak voltage are the largest influence of parameters on cutting speed. With WEDM optimized parameters, a quadrilateral PCD micro milling tool is fabricated with CTB002 PCD material. Tool edge radius is 6.7 m.