Fabrication of PCD micro end mill for machining hard and brittle material

Abstract

The fabrication of a superhard diamond tool is the key factor for micro milling of miniature parts made of hard and brittle material. In this paper, the polycrystalline diamond (PCD) micro end mill is fabricated with three steps. First, the PCD plate is welded on the tool shank with the high-frequency induction welding process. Then, the PCD micro end mill is pre-formed with wire electrical discharge machining to generate its main shape and structure. Finally, the PCD micro end mill is further sharpened with a diamond wheel to improve the tool quality. The multistep fabrication process for mass producing the PCD tool can obtain the satisfied efficiency and tool quality. The tool performance is evaluated with micro milling experiments on cemented carbide. The machined surface free of brittle fracture defects is achieved.