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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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.