Comparative Study of Ultrasonic Vibration-Assisted Die-Sinking Micro-Electrical Discharge Machining on Polycrystalline Diamond and Titanium
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2024-03-25 |
| Journal | Micromachines |
| Authors | Cheng Guo, Longhui Luo, Zhiqiang Liang, Hao Li, Xiawen Wang |
| Institutions | Beijing Institute of Technology, Shenzhen University |
| Citations | 1 |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: Ultrasonic Vibration-Assisted Micro-EDM of Diamond
Section titled âTechnical Documentation & Analysis: Ultrasonic Vibration-Assisted Micro-EDM of DiamondâExecutive Summary
Section titled âExecutive SummaryâThis research provides critical insights into optimizing die-sinking micro-Electrical Discharge Machining (”-EDM) of Polycrystalline Diamond (PCD) using ultrasonic vibration, a key process for fabricating intricate diamond structures.
- PCD Efficiency Enhancement: At low energy (100 V open-circuit voltage), ultrasonic vibration significantly promotes PCD material removal rate (MRR), achieving increases of 3 to 5 times, peaking at 0.0022 mm³/min (22 nF, 20 Ω).
- Mechanism (PCD): The promotion is attributed to the cavitation effect, which improves the inter-electrode gap environment by accelerating the removal of graphite and cobalt debris, facilitating continuous electrode movement.
- High Energy Inhibition: At high energy (200 V), ultrasonic vibration generally exhibits an inhibitory effect on PCD ”-EDM, disrupting the stable discharge state achieved at high voltage/low resistance parameters.
- Material Differentiation: The effect of ultrasonic assistance differs fundamentally between PCD (poor conductivity, resistant to arcing) and TA2 (poor thermal conductivity, susceptible to arcing).
- TA2 Promotion: For Titanium (TA2), ultrasonic vibration consistently promotes MRR at both 100 V and 200 V by actively disrupting the electrical arc and accelerating heat transfer away from the discharge zone.
- Process Optimization: To maximize efficiency, the ultrasonic amplitude must be dynamically adjusted based on material type, discharge energy level, and machining depth.
- 6CCVD Value: 6CCVD provides the high-purity MPCVD PCD and SCD materials necessary to replicate and advance this research, offering custom dimensions and integrated metalization solutions for optimized electrode performance.
Technical Specifications
Section titled âTechnical SpecificationsâThe following table summarizes the key experimental parameters and performance metrics extracted from the study, focusing on the PCD results.
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Max MRR (PCD, w/ US) | 0.0022 | mm³/min | Achieved at Ve=100 V, C=22 nF, Rc=20 Ω. |
| MRR Increase (PCD, 100 V) | 3 to 5 | times | Increase relative to non-ultrasonic ”-EDM. |
| Open-Circuit Voltage (Ve) | 100, 200 | V | Primary machining voltages tested. |
| Discharge Capacitance (C) | 1.5, 4.7, 10, 22 | nF | RC power supply parameters. |
| Discharge Resistance (Rc) | 12, 20, 50, 100 | Ω | RC power supply parameters. |
| Ultrasonic Frequency | 21,714 | Hz | Applied vertical vibration frequency. |
| Ultrasonic Amplitude | 2 to 3 | ”m | Range of vertical vibration amplitude. |
| PCD Layer Thickness | ~0.5 | mm | Sintered onto a hard alloy matrix. |
| Electrode Wear (PCD, 100 V, 1.5 nF, 12 Ω) | 30 vs 10 | ”m | With US vs. Without US (US increases wear). |
| Minimum Discharge Crater Diameter (TA2) | < 10 | ”m | Observed at 100 V, 10 nF, 100 Ω (high resistance). |
Key Methodologies
Section titled âKey MethodologiesâThe experimental approach utilized a specialized die-sinking micro-EDM setup integrated with ultrasonic vibration control to compare machining performance on PCD and TA2.
- Material Preparation: Polycrystalline Diamond (PCD) samples (10 mm x 10 mm x 2 mm, 0.5 ”m PCD layer on hard alloy) and pure Titanium (TA2) blocks were mechanically polished and cleaned via ultrasonic methods.
- Tool Electrode Fabrication: Sheet tool electrodes (100 ”m thickness) were fabricated from W70Cu30 tungsten-copper alloy using wire-cutting techniques.
- Experimental Setup: A die-sinking micro-EDM system was employed, featuring an RC power supply and an ultrasonic control unit. The workpiece was fully immersed in spark oil dielectric.
- Ultrasonic Application: An ultrasonic tool holder generated vertical vibration at 21,714 Hz, with amplitudes ranging from 2 to 3 ”m, applied directly to the electrode.
- Parameter Sweep: Experiments systematically varied the open-circuit voltage (100 V and 200 V) and the RC circuit parameters (Capacitance: 1.5-22 nF; Resistance: 12-100 Ω).
- Performance Analysis: Machining outcomes were quantified by measuring Material Removal Rate (MRR), analyzing discharge waveforms (effective discharge counts), and characterizing surface topography (SEM imaging of craters and groove profiles).
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & Capabilitiesâ6CCVD is uniquely positioned to supply the advanced MPCVD diamond materials and custom fabrication services required to replicate, optimize, and extend the findings of this ultrasonic micro-EDM research.
| Research Requirement/Challenge | 6CCVD Solution & Value Proposition |
|---|---|
| PCD Material Source & Purity | High-Purity MPCVD PCD Wafers: The study used a thin PCD layer on a hard alloy matrix. 6CCVD supplies high-quality, freestanding Polycrystalline Diamond (PCD) plates up to 125 mm in diameter. Our PCD is available in thicknesses from 0.1 ”m to 500 ”m, ensuring uniform material properties critical for consistent ”-EDM results. |
| High-Precision Micro-Machining | Optical Grade Single Crystal Diamond (SCD): For applications requiring the highest thermal stability and surface finish (Ra < 1 nm), 6CCVD offers SCD substrates (up to 10 mm thick). SCDâs superior thermal properties compared to PCD will fundamentally alter the thermal dissipation dynamics during ”-EDM, providing a crucial comparative material for advanced studies. |
| Electrode Wear & Stability | Custom Metalization Services: The research noted high electrode wear (up to 30 ”m) with ultrasonic assistance. 6CCVD offers in-house metalization capabilities (Au, Pt, Pd, Ti, W, Cu) on diamond surfaces. Researchers can utilize our services to develop novel, wear-resistant diamond-based electrodes or integrated tool tips for high-frequency ultrasonic ”-EDM. |
| Custom Dimensions & Integration | Precision Fabrication & Large Format: We provide custom laser cutting and shaping for plates/wafers up to 125 mm (PCD). Whether you require 10 mm x 10 mm samples or larger substrates for industrial scale-up, 6CCVD ensures precise dimensions and ultra-low surface roughness (Ra < 5 nm for inch-size PCD). |
| BDD for Enhanced Conductivity | Boron-Doped Diamond (BDD): For experiments requiring controlled electrical conductivity, 6CCVD supplies BDD films. BDD can be used as a highly conductive electrode material or as a workpiece material to study the effects of conductivity on arc suppression and debris removal in ultrasonic ”-EDM. |
| Process Optimization Guidance | Expert Engineering Support: Our in-house PhD team specializes in CVD diamond material science and processing. We offer consultation to assist engineers and scientists in selecting the optimal diamond grade and defining the precise material specifications needed to achieve maximum MRR and minimal tool wear in complex ultrasonic vibration-assisted micro-EDM projects. |
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly. We ship globally (DDU default, DDP available).
View Original Abstract
Die-sinking micro-electrical discharge machining (micro-EDM) is a potential method used to fabricate intricate structures without complex electrode motion planning and compensation. However, machining efficiency and poor discharge states are still bottlenecks. This study conducted a comparative investigation into the impact of ultrasonic vibration on die-sinking micro-EDM of polycrystalline diamond (PCD) and pure titanium (TA2). By adjusting discharge parameters, this study systematically evaluated the influence of ultrasonic vibration on these two materials based on discharge waveforms, motion trajectories, effective discharge counts and groove profiles. At an open-circuit voltage of 100 V, ultrasonic vibration promotes die-sinking micro-EDM of PCD. However, when the open-circuit voltage increases to 200 V, ultrasonic vibration exhibits inhibitory effects in general. Conversely, for TA2, ultrasonic vibration shows a promoting effect at both voltages, indicating the differences of ultrasonic vibration-assisted die-sinking micro-EDM on PCD and TA2. For PCD, ultrasonic cavitation improves the discharge gap environment, accelerating the removal of discharge debris. For TA2, due to its poor thermal conductivity, ultrasonic cavitation acts to break the arc, accelerating heat transfer. These research findings provide guidance for ultrasonic vibration-assisted die-sinking micro-EDM in industrial applications.
Tech Support
Section titled âTech SupportâOriginal Source
Section titled âOriginal SourceâReferences
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- 2002 - Study on PCD Machining [Crossref]
- 2020 - The Manufacturing and the Application of Polycrystalline Diamond ToolsâA Comprehensive Review [Crossref]
- 2020 - Machining Characteristics of PCD by EDM with Cu-Ni Composite Electrode [Crossref]