Micro Three-Dimensional Cavities Tools Fabrication on PCD by µ-EDM Scanning Process

Abstract

This study describes the use of micro electro-discharge machining (µ-EDM) scanning technology to fabricate micro three-dimensional cavities and microtools fabrication on polycrystalline diamonds (PCD). The experimental results show that short-pulse discharge from an resistor-capacitor (RC) circuit is more effective and precise than a transistor (Tr) pulse generator while machining PCDs by µ-EDM. The surface roughness of PCD using the µ-EDM scanning process could be as small as Ra 0.2 µm, even when the diamond grain size is considerably larger. Moreover, small PCD tools for cutting brittle materials could be easily fabricated by the same µ-EDM process. Thanks to their hardness and excellent thermal conductivity, PCDs could be utilized in the near future, not only for micro molds, but also for tools to cut brittle material.