Fabrication method of polycrystalline diamond micro-drill using a hybrid process of pulsed laser, EDM and precision grinding

IF 4.2 2区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

International Journal of Refractory Metals & Hard Materials Pub Date : 2025-02-25 DOI:10.1016/j.ijrmhm.2025.107124

Yue Ma , Zhiqiang Liang , Yuchao Du , Zhipeng Su , Jinkai Xu , Cheng Guo , Shuying Zhang , Haofei Guo , Pengwan Chen

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引用次数: 0

Abstract

Super-hard tool materials such as polycrystalline diamond (PCD) have become advanced materials for fabricating high-performance micro cutting tool. Due to the limitation of the complex tool structure, the tool dimension and the difficult machining characteristics of PCD material, the efficient precision fabrication of PCD micro-drill is still an urgent problem to be solved. Therefore, a new laser-EDM-grinding hybrid fabrication method is proposed to prepare the PCD micro-drill in this study. Firstly, the diameter reduction machining of micro-drill cylindrical surface is conducted by picosecond pulse laser, and the preform machining of micro-drill flute is realized by EDM. Finally, the precision grinding is used to form the high-quality edge structures of micro-drill. The effects of laser and EDM parameters on the fabrication quality of PCD micro-drill are investigated respectively, and the formation mechanism of tool surface micromorphology under these two fabrication methods is analyzed. The PCD micro-drill with a diameter of 0.4 mm and a cutting edge radius of 1.164 μm is fabricated with the optimized machining parameters, then the drilling performance of the self-fabricated PCD micro-drill is studied by micro-hole drilling experiment on monocrystalline silicon materials. The micro-drilling experiment results verify that the self-fabricated PCD micro-drill has obvious advantages in micro-hole processing quality.

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脉冲激光、电火花加工和精密磨削复合加工多晶金刚石微钻的方法

聚晶金刚石（PCD）等超硬刀具材料已成为制造高性能微刀具的先进材料。由于PCD材料复杂的刀具结构、刀具尺寸和难加工特性的限制，PCD微钻的高效精密加工仍然是一个亟待解决的问题。因此，本研究提出了一种新的激光-电火花-磨削复合加工方法来制备PCD微钻。首先，利用皮秒脉冲激光对微钻圆柱表面进行了减径加工，利用电火花加工实现了微钻凹槽的预成形加工。最后通过精密磨削加工，形成高质量的微钻刃口结构。分别研究了激光和电火花加工参数对PCD微钻加工质量的影响，并分析了两种加工方式下刀具表面微观形貌的形成机理。利用优化后的加工参数制备了直径为0.4 mm、刃口半径为1.164 μm的PCD微钻，并在单晶硅材料上进行了微孔钻削实验，研究了自制PCD微钻的钻削性能。微孔实验结果表明，自制PCD微钻在微孔加工质量上具有明显优势。

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来源期刊

$International Journal of Refractory Metals & Hard Materials$

International Journal of Refractory Metals & Hard Materials 工程技术-材料科学：综合

CiteScore

7.00

自引率

13.90%

发文量

236

审稿时长

35 days

期刊介绍： The International Journal of Refractory Metals and Hard Materials (IJRMHM) publishes original research articles concerned with all aspects of refractory metals and hard materials. Refractory metals are defined as metals with melting points higher than 1800 °C. These are tungsten, molybdenum, chromium, tantalum, niobium, hafnium, and rhenium, as well as many compounds and alloys based thereupon. Hard materials that are included in the scope of this journal are defined as materials with hardness values higher than 1000 kg/mm2, primarily intended for applications as manufacturing tools or wear resistant components in mechanical systems. Thus they encompass carbides, nitrides and borides of metals, and related compounds. A special focus of this journal is put on the family of hardmetals, which is also known as cemented tungsten carbide, and cermets which are based on titanium carbide and carbonitrides with or without a metal binder. Ceramics and superhard materials including diamond and cubic boron nitride may also be accepted provided the subject material is presented as hard materials as defined above.