Skip to main content

Advertisement

Log in

Electrical discharge grinding versus abrasive grinding in polycrystalline diamond machining—tool quality and performance analysis

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Electrical discharge grinding (EDG) and conventional abrasive grinding are two different methods to machine polycrystalline diamond (PCD) with different removal mechanisms. This paper discussed the quality issues of PCD tools produced by the two processes. Although remarkably similar surface roughness and tool sharpness were obtained in both processes, it was found that residual stress and the level of graphitization were significantly different. In this study, residual stress and graphitization were analyzed quantitatively with the Raman method. Maximum compression residual stress of 1.4 GPa was recorded in the abrasively ground PCD of the smallest grade size while minimum compression residual stress of 0.7 GPa was found in the PCD of the biggest grade. On the contrary, the dominant residual stress in the EDG-eroded PCDs was tensile stress and its magnitude was in the range of 4.7 to 0.4 GPa. Through cutting tests, it was revealed that the residual stress and graphitization influenced the wear mechanism of the tool. It was also observed that abrasive wear dominated the wear pattern of the highly graphitized PCD tools, while breakage through fracture was the main wear mechanism for abrasively ground PCD, which has a structure of lower-level graphitization.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Tso P-L, Liu Y-G (2002) Study on PCD machining. Int J Mach Tools Manuf 42(3):331–334. doi:10.1016/s0890-6955(01)00131-6

    Article  Google Scholar 

  2. Liu Y-K, Tso P-L (2003) The optimal diamond wheels for grinding diamond tools. Int J Adv Manuf Technol 22(5–6):396–400

    Article  Google Scholar 

  3. Dold C, Henerichs M, Bochmann L, Wegener K (2012) Comparison of ground and laser machined polycrystalline diamond (PCD) tools in cutting carbon fiber reinforced plastics (CFRP) for aircraft structures. Proc CIRP 1:178–183. doi:10.1016/j.procir.2012.04.031

    Article  Google Scholar 

  4. Ishimarua D, Tougea M, Mutaa H, Kubota A, Sakamoto T, Sakamoto S (2012) Burr suppression using sharpened PCD cutting edge by ultraviolet-ray irradiation assisted polishing. Proc CIRP 1:184–189

    Article  Google Scholar 

  5. Karpat Y, Değer B, Bahtiyar O (2014) Experimental evaluation of polycrystalline diamond tool geometries while drilling carbon fiber-reinforced plastics. Int J Adv Manuf Technol 71(5–8):1295–1307. doi:10.1007/s00170-013-5592-7

    Article  Google Scholar 

  6. Pan W, Ding S, Mo J (2014) Thermal characteristics in milling Ti6Al4V with polycrystalline diamond tools. Int J Adv Manuf Technol 75(5–8):1077–1087. doi:10.1007/s00170-014-6094-y

    Article  Google Scholar 

  7. Izamshah R, Mo J, Ding S (2011) Hybrid deflection prediction on machining thin-wall monolithic aerospace components. Proc Inst Mech Eng B J Eng Manuf 0954405411425443

  8. Hu B, Lim C, Ding SL, Rahim MZ, Brandt M, Mo J (2015) Experimental study of wheel rotating speed effect on electrical discharge grinding. In: Applied mechanics and materials. Trans Tech Publ, 275–279

  9. Xia T, Kaynak Y, Arvin C, Jawahir IS (2015) Cryogenic cooling-induced process performance and surface integrity in drilling CFRP composite material. Int J Adv Manuf Technol:1–12. doi:10.1007/s00170-015-7284-y

  10. Suzuki K, Saito T, Sano S, Iwai M, Ninomiya S, Uematsu T (2007) Manufacturing of a porous PCD with skeleton structure by EDM. 電気加工学会全国大会講演論文集 2007:58–63

  11. Giménez S, Van der Biest O, Vleugels J (2007) The role of chemical wear in machining iron based materials by PCD and PCBN super-hard tool materials. Diam Relat Mater 16(3):435–445

    Article  Google Scholar 

  12. Iwai M, Sano S, Pan W, Itagaki K, Murakami Y, Wang M, Uematsu T, Suzuki K (2006) Manufacturing of micro V-groove with an electrically conductive diamond electrode in EDM. In: American Society for Precision Engineering 21st Annual Meeting. American Society for Precision Engineering, Monterey

  13. Kuppuswamy R, Airey K-A, Sardikmen H (2014) Micro-grinding characteristics of polycrystalline diamond tool. Int J Adv Manuf Techn:1–11

  14. Zulafif Rahim M, Ding S, Mo J (2015) Electrical discharge grinding of polycrystalline diamond—effect of machining parameters and finishing in-feed. J Manuf Sci Eng 137(2):021017–021017. doi:10.1115/1.4029433

    Article  Google Scholar 

  15. Wyen C-F, Wegener K (2010) Influence of cutting edge radius on cutting forces in machining titanium. CIRP Ann-Manuf Technol 59(1):93–96

    Article  Google Scholar 

  16. Catledge SA, Vohra YK, Ladi R, Rai G (1996) Micro-raman stress investigations and X-ray diffraction analysis of polycrystalline diamond (PCD) tools. Diam Relat Mater 5(10):1159–1165. doi:10.1016/0925-9635(96)00534-1

    Article  Google Scholar 

  17. Liu K, Li XP, Rahman M, Liu XD (2004) Study of ductile mode cutting in grooving of tungsten carbide with and without ultrasonic vibration assistance. Int J Adv Manuf Technol 24(5–6):389–394. doi:10.1007/s00170-003-1647-5

    Article  Google Scholar 

  18. Hintze W, Frömming H, Dethlefs A (2010) Influence of machining with defined cutting edge on the subsurface microstructure of WC–Co parts. Int J Refract Met Hard Mater 28(2):274–279. doi:10.1016/j.ijrmhm.2009.10.012

    Article  Google Scholar 

  19. Nakamoto K, Katahira K, Ohmori H, Yamazaki K, Aoyama T (2012) A study on the quality of micro-machined surfaces on tungsten carbide generated by PCD micro end-milling. CIRP Ann Manuf Technol 61(1):567–570. doi:10.1016/j.cirp.2012.03.112

    Article  Google Scholar 

  20. Harano K, Satoh T, Sumiya H, S-t KUKINO (2010) Cutting performance of nano-polycrystalline diamond. SEI Tech Rev 77:98–103

    Google Scholar 

  21. Wang D, Zhao WS, Gu L, Kang XM (2011) A study on micro-hole machining of polycrystalline diamond by micro-electrical discharge machining. J Mater Process Technol 211(1):3–11. doi:10.1016/j.jmatprotec.2010.07.034

    Article  Google Scholar 

  22. Shin TJ, Oh JO, Hwan Oh K, Lee DN (2004) The mechanism of abnormal grain growth in polycrystalline diamond during high pressure-high temperature sintering. Diam Relat Mater 13(3):488–494

    Article  Google Scholar 

  23. Uehara K, Yamaya S (1990) High pressure sintering of diamond by cobalt infiltration. Science and Technology of New Diamond. In: Satio, S et al. (Eds.) Tokio: KTK Scientific Publishers/Terra Scientific Publishing Company (TERRAPUB):203–209

  24. Erasmus RM, Comins JD, Mofokeng V, Martin Z (2011) Application of Raman spectroscopy to determine stress in polycrystalline diamond tools as a function of tool geometry and temperature. Diam Relat Mater 20(7):907–911. doi:10.1016/j.diamond.2011.03.018

    Article  Google Scholar 

  25. Field J (2012) The mechanical and strength properties of diamond. Rep Prog Phys 75(12):126505

    Article  Google Scholar 

  26. Jaworska L, Szutkowska M, Klimczyk P, Sitarz M, Bucko M, Rutkowski P, Figiel P, Lojewska J (2014) Oxidation, graphitization and thermal resistance of PCD materials with the various bonding phases of up to 800°C. Int J Refract Met Hard Mater 45:109–116. doi:10.1016/j.ijrmhm.2014.04.003

    Article  Google Scholar 

  27. Mlungwane K, Herrmann M, Sigalas I (2008) The low-pressure infiltration of diamond by silicon to form diamond–silicon carbide composites. J Eur Ceram Soc 28(1):321–326

    Article  Google Scholar 

  28. Li L, Zhu Z, Yan Z, Lu G, Rintoul L (2007) Catalytic ammonia decomposition over Ru/carbon catalysts: the importance of the structure of carbon support. Appl Catal A Gen 320:166–172

    Article  Google Scholar 

  29. Yingfei G, Jiuhua X, Hui Y (2010) Diamond tools wear and their applicability when ultra-precision turning of SiC p/2009Al matrix composite. Wear 269(11):699–708

    Article  Google Scholar 

  30. Ali M, Ürgen M, Atta M (2012) Effect of surface treatment on hot-filament chemical vapour deposition grown diamond films. J Phys D Appl Phys 45(4):045301

    Article  Google Scholar 

  31. Chen Y, Zhang LC, Tang F (2012) Surface integrity of PCD composites generated by dynamic friction polishing: effect of processing conditions. Diam Relat Mater 26:25–31. doi:10.1016/j.diamond.2012.04.002

    Article  Google Scholar 

  32. Chen Y, Zhang L (2013) Quality verification of polished PCD composites by examining the phase transformations. In: IUTAM Symposium on Surface Effects in the Mechanics of Nanomaterials and Heterostructures. Springer, 147–156

  33. Chen Y, Zhang LC (2009) Polishing of polycrystalline diamond by the technique of dynamic friction, part 4: establishing the polishing map. Int J Mach Tools Manuf 49(3–4):309–314. doi:10.1016/j.ijmachtools.2008.10.010

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Mohammad Zulafif Rahim.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Rahim, M.Z., Li, G., Ding, S. et al. Electrical discharge grinding versus abrasive grinding in polycrystalline diamond machining—tool quality and performance analysis. Int J Adv Manuf Technol 85, 263–277 (2016). https://doi.org/10.1007/s00170-015-7935-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7935-z

Keywords

Navigation