EDM-Grinding composite machining and drilling of polycrystalline diamond tool

Polycrystalline diamond (PCD) is widely used for micro tools due to its high hardness and wear resistance. However, micro PCD tools face challenges in machining with high accuracy and efficiency. Therefore, electrical discharge machining grinding (EDM-grinding) composite machining was proposed. The effects of pulse discharge parameters on surface quality and microhole drilling performance of PCD tool were investigated. The results show that the surface roughness of helix flute and flank face of the fabricated PCD tool were 0.125 mu m and 0.158 mu m, respectively, as well as the inner wall roughness achieved 0.331 mu m after drilling of microhole. The average current displayed a greater effect on the machining quality of PCD tools, with tool breakage in excessive average current. The preferred pulse discharge parameters were determined as an open-circuit voltage of 95 V, an average current of 1400 mA, a pulse width of 400 ns, and a pulse interval of 2000 ns.