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Research Papers

Electrical Discharge Grinding of Polycrystalline Diamond—Effect of Machining Parameters and Finishing In-Feed

[+] Author and Article Information
M. Zulafif Rahim

School of Aerospace,
Mechanical and Manufacturing Engineering,
RMIT University East Campus,
Melbourne, VIC 3083, Australia;
Faculty of Mechanical
and Manufacturing Engineering,
Universiti Tun Hussein Onn Malaysia (UTHM),
P.O. Box 101, Parit Raja,
Batu Pahat 86400, Johor, Malaysia
e-mail: mohammadzulafif.rahim@rmit.edu.au

Songlin Ding

Senior Lecturer
School of Aerospace,
Mechanical and Manufacturing Engineering,
RMIT University East Campus,
Melbourne, VIC 3083, Australia
e-mail: songlin.ding@rmit.edu.au

John Mo

Professor
School of Aerospace,
Mechanical and Manufacturing Engineering,
RMIT University East Campus,
Melbourne, VIC 3083, Australia
e-mail: john.mo@rmit.edu.au

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received June 20, 2014; final manuscript received December 15, 2014; published online February 4, 2015. Assoc. Editor: Y.B. Guo.

J. Manuf. Sci. Eng 137(2), 021017 (Apr 01, 2015) (11 pages) Paper No: MANU-14-1333; doi: 10.1115/1.4029433 History: Received June 20, 2014; Revised December 15, 2014; Online February 04, 2015

Electrical discharge grinding (EDG) is becoming more prevalent in the manufacturing of polycrystalline diamond (PCD) tools. This paper concerns investigation of the effects of machining parameters, as well as finishing in-feed, to the surface quality obtained when using EDG to erode PCD. With the aid of the morphological findings, different PCD erosion mechanisms are discussed. Experimental results demonstrated that the eroded surface quality of PCD was significantly affected by the selected parameters. High temperature due to the erosion process resulted in the partial conversion of diamond to graphite phase under the surface. Higher finishing in-feed produced better surface quality and caused lower surface graphitization and lower tensile residual stress. A model for the thermal stress prediction was developed and found to have good agreement with the experimental findings.

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Figures

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Fig. 1

Three phases of the residual stress development in PCD tools production

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Fig. 2

SEM images of the PCD after roughing (modified zone was clearly observed on the 12 A PCD sample)

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Fig. 3

Secondary electron (left) and Backscatter Image (right) of modified zone for 12 A PCD sample

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Fig. 5

Secondary electron images (left) and backscatter images (right) of the eroded PCD by roughing

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Fig. 6

Thermal stress components considered in the model (r = position where the stress value is estimated, a = diamond grain radius, σ = stress component for tangential, t and radial, r direction) [15]

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Fig. 7

Temperature dependent properties of diamond

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Fig. 8

Current, voltage spark radius, and heat flux value used in the model

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Fig. 9

Scheme for the boundary conditions

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Fig. 10

Temperature dependent properties calculated

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Fig. 11

Temperature–stress relationship for different PCD

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Fig. 12

Diamond breakage mechanism

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Fig. 13

Eroded surface after the finishing operation

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Fig. 14

Raman D-value (a) CTX002, (b) CTB010, and (c) CTM302

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Fig. 15

D/G ratio (a) CTX002, (b) CTB010, and (c) CTM302

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Fig. 16

A comparison of graphitization degree of three different PCD

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