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WEDM condition parameter optimization for PCD microtool geometry fabrication process and quality improvement

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Abstract

To increase fabrication efficiency for poly-crystalline diamond (PCD) microtools, wire EDM technology was applied and optimized by using a design of experimentation. For roughing, the productivity must be maximized while for finishing, the surface roughness must be minimized to achieve the best overall quality. Using three different grades of PCD, experimental results show a significant increase in productivity with no significant decrease in microtool quality, which was confirmed by hexagonal end-mill fabrication using both non-optimized and optimized conditions.

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Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, University of California, Davis, One Shields Avenue, Davis, CA, 95616, USA

    Peter Fonda, Kazutoshi Katahira & Kazuo Yamazaki

  2. Materials Fabrication Laboratory, RIKEN, Wako-shi Hirosawa 2-1, Saitama, 351-0198, Japan

    Kazutoshi Katahira

  3. Sumitomo Electric Hardmetal Corporation, Itami-shi Koyakita 1-1-1, Hyogo, 664-0016, Japan

    Yutaka Kobayashi

Authors
  1. Peter Fonda
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  2. Kazutoshi Katahira
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  3. Yutaka Kobayashi
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  4. Kazuo Yamazaki
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Correspondence to Peter Fonda.

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Fonda, P., Katahira, K., Kobayashi, Y. et al. WEDM condition parameter optimization for PCD microtool geometry fabrication process and quality improvement. Int J Adv Manuf Technol 63, 1011–1019 (2012). https://doi.org/10.1007/s00170-012-3977-7

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  • DOI: https://doi.org/10.1007/s00170-012-3977-7

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