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Sensors and Materials
is an international peer-reviewed open access journal to provide a forum for researchers working in multidisciplinary fields of sensing technology.
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Sensors and Materials, Volume 36, Number 9(2) (2024)
Copyright(C) MYU K.K.
pp. 3797-3815
S&M3768 Research Paper of Special Issue
https://doi.org/10.18494/SAM5097
Published: September 5, 2024

On-machine Fabrication of Boron-doped Polycrystalline Diamond Cutting Tools by Combining Wire Electrical Discharge Machining and Abrasive Grinding [PDF]

Yue-Feng Lin, Pei-Yu Lai, and Yuan-Xiu Luo

(Received April 30, 2024; Accepted July 18, 2024)

Keywords: boron-doped polycrystalline diamond, microcutting tool, wire-EDM, abrasive grinding, cutting edge, CCD

A sequential technique that combines wire electrical discharge machining (wire-EDM) and abrasive grinding on dedicated equipment improves the edge quality of boron-doped polycrystalline diamond (BD-PCD) cutting tools. In this study, we focus on material removal mechanisms during BD-PCD machining and surface graphitization caused by wire-EDM thermal damage. Surface topography is used to distinguish ductile- and brittle-regime grinding in tool production. Resin-bonded diamond wheels outperform electroplated diamond wheels in abrasive grinding owing to their self-sharpening capabilities. The experimental results show that BD-PCD tools have higher mechanical properties and performance than standard PCD tools. Maximum edge chipping on BD-PCD surfaces depends on the depth of cut and grinding speed. Microgrinding experiments on BK7 glass reveal that the recommended tool manufacturing approach, which merges wire-EDM and abrasive grinding, results in high-quality surfaces free of microcracks and achieves a surface roughness of 6 nm Sa. Abrasion on the flank face and chipping on the periphery are the main wear patterns on grinding tools. In this study, we improve our understanding of BD-PCD microcutter production, focusing on parameter management for optimal surface quality, edge integrity, and tool performance. We emphasize the necessity of choosing the right grinding wheel to achieve the necessary surface and subsurface quality when making microcutting tools. Raman spectroscopy results are used to explain thermal deterioration when diamond grains turn into graphite at high manufacturing temperatures. We address the challenges of producing high-quality microcutting tools and offer insights into improving BD-PCD tool performance and edge quality.

Corresponding author: Yue-Feng Lin


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Cite this article
Yue-Feng Lin, Pei-Yu Lai, and Yuan-Xiu Luo, On-machine Fabrication of Boron-doped Polycrystalline Diamond Cutting Tools by Combining Wire Electrical Discharge Machining and Abrasive Grinding, Sens. Mater., Vol. 36, No. 9, 2024, p. 3797-3815.



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