The influence of graphitization catalyst electrode in electrical discharge machining of polycrystalline diamond-finishing condition

Electrical Discharge Machining (EDM) is a non-contact machining process that becomes famous in machining of Polycrystalline Diamond (PCD). The material is typically used as the cutting tools for aerospace and automotive industries. However, low electrical conductivity and high melting temperature of PCD has caused slower EDM process. This investigation purposely designed to investigate the influence of different types of electrode which are Copper (ordinary electrode) and Copper-Nickel (newly proposed graphitization catalyst electrode) on EDM performance of MRR and Ra. Interestingly the newly proposed electrode gave positive impact to the investigated performance indication. Cu-Ni electrode recorded 35% better in MRR than the Cu electrode, though with higher short-circuiting rate. Cu-Ni also provided the lowest Ra value with 10% better than the best Ra produced by Cu electrode. This phenomenon occurred as due to the high interaction between the catalyst materials of nickel and diamond which supported by the qualification data provided in this investigation

Electrical discharge machining of polycrystalline diamond using copper electrode – finishing condition

Research on machining process of Polycrystalline Diamond (PCD) is becoming important as the material was believed suitable to be used for cutting tools of advanced aeronautical structure. Electrical Discharge Machining (EDM) was regarded as the suitable method to machine PCD due its noncontact process nature. The objective of this research is to determine the influence of several EDM parameter such as sparking current, pulse duration, and pulse interval to the material removal rate and surface roughness of the machined PCD. Instead of significantly influenced the material removal rate, the sparking current was also highly influenced tha surface roughness. Highest material removal rate of approximately 0.005mm3/s was recorded by the EDM process with the highest current used of 5A, and lowest pulse interval of 1µs. The influence of pulse duration is not clearly seen at the lowest pulse interval used. On the other hand, 0.4µm was the lowest surface roughness value obtained in this research indicated by the highest sparking current, highest sparking duration and lowest sparking interval of 5A, 1µs and 1µs respectively

Electrical discharge machining of polycrystalline diamond using copper electrode – finishing condition

Research on machining process of Polycrystalline Diamond (PCD) is becoming important as the material was believed suitable to be used for cutting tools of advanced aeronautical structure. Electrical Discharge Machining (EDM) was regarded as the suitable method to machine PCD due its noncontact process nature. The objective of this research is to determine the influence of several EDM parameter such as sparking current, pulse duration, and pulse interval to the material removal rate and surface roughness of the machined PCD. Instead of significantly influenced the material removal rate, the sparking current was also highly influenced tha surface roughness. Highest material removal rate of approximately 0.005mm3/s was recorded by the EDM process with the highest current used of 5A, and lowest pulse interval of 1µs. The influence of pulse duration is not clearly seen at the lowest pulse interval used. On the other hand, 0.4µm was the lowest surface roughness value obtained in this research indicated by the highest sparking current, highest sparking duration and lowest sparking interval of 5A, 1µs and 1µs respectively