Experimental study on the wire electrical discharge machining of PCD with different grain sizes

IF 4.3 3区材料科学 Q2 MATERIALS SCIENCE, COATINGS & FILMS

Diamond and Related Materials Pub Date : 2025-04-11 DOI:10.1016/j.diamond.2025.112331

Kechuang Zhang , Laifa Zhu , Zhongwei Chen , Jianyun Shen , Xuefeng Zhao , Xian Wu

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Abstract

Polycrystalline diamond (PCD), known for its high hardness and wear resistance, is widely used as various cutting tools. As extremely difficult to machine materials, the wire electrical discharge machining (WEDM) is widely applied to cut PCD material. In this work, the material removal mechanism during WEDM of PCD materials is studied and the effect of grain size of PCD materials on WEDM performance is further analyzed. The results indicate that the material removal rate tends to decrease with the increase of grain size. The PCD materials with smaller grain size can effectively reduce the cutting difficulty, and the highest material rate can reach 1.769 mm³/min. Additionally, the cutting surface roughness of three PCD composites was affected by the grain size. The medium grain is prone to surface degradation during machining, resulting in the worst surface quality. The surface roughness of the medium grain PCD material was 67.51 % higher than that of the fine grain. Finally, the effect on the depth of the electro-erosion layer was further observed and analyzed. The overall average depth of the electro-etched layer for PCD materials with fine grain size reached the lowest 0.007 mm. These results provide theoretical support for the WEDM process of PCD materials, which contributes to improve machining efficiency and product quality.

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不同粒度PCD的线切割加工试验研究

聚晶金刚石（PCD）以其高硬度和耐磨性被广泛用作各种切削工具。作为一种极难加工的材料，线切割加工被广泛应用于PCD材料的切割。本文研究了PCD材料在电火花切割过程中的材料去除机理，并进一步分析了PCD材料的晶粒尺寸对电火花切割性能的影响。结果表明：随着晶粒尺寸的增大，材料去除率有降低的趋势；晶粒尺寸较小的PCD材料可有效降低切削难度，最高出料率可达1.769 mm3/min。此外，三种PCD复合材料的切削表面粗糙度受晶粒尺寸的影响。中晶粒在加工过程中容易发生表面退化，导致表面质量最差。中晶粒PCD材料的表面粗糙度比细晶粒PCD材料的表面粗糙度高67.51%。最后，对电侵蚀层深度的影响进行了进一步的观察和分析。细晶粒PCD材料的电蚀层总体平均深度最低，为0.007 mm。研究结果为PCD材料的线切割加工提供了理论支持，有助于提高加工效率和产品质量。

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来源期刊

Diamond and Related Materials 工程技术-材料科学：综合

CiteScore

6.00

自引率

14.60%

发文量

702

审稿时长

2.1 months

期刊介绍： DRM is a leading international journal that publishes new fundamental and applied research on all forms of diamond, the integration of diamond with other advanced materials and development of technologies exploiting diamond. The synthesis, characterization and processing of single crystal diamond, polycrystalline films, nanodiamond powders and heterostructures with other advanced materials are encouraged topics for technical and review articles. In addition to diamond, the journal publishes manuscripts on the synthesis, characterization and application of other related materials including diamond-like carbons, carbon nanotubes, graphene, and boron and carbon nitrides. Articles are sought on the chemical functionalization of diamond and related materials as well as their use in electrochemistry, energy storage and conversion, chemical and biological sensing, imaging, thermal management, photonic and quantum applications, electron emission and electronic devices. The International Conference on Diamond and Carbon Materials has evolved into the largest and most well attended forum in the field of diamond, providing a forum to showcase the latest results in the science and technology of diamond and other carbon materials such as carbon nanotubes, graphene, and diamond-like carbon. Run annually in association with Diamond and Related Materials the conference provides junior and established researchers the opportunity to exchange the latest results ranging from fundamental physical and chemical concepts to applied research focusing on the next generation carbon-based devices.