Precise Machining Method by Combining EDM and Grinding with a Rotary PCD Segment Tool for Cemented Carbide

Abstract

In our previous research, precise groove machining could be achieved on a cemented carbide workpiece by utilizing a combined method of EDM and grinding using only a single tool, i.e. a rotary PCD disc tool acting as an electrode for EDM and as a wheel for grinding. In this study, the authors applied this method to forming a 3D shape on a cemented carbide workpiece. Firstly, an EC-PCD disc-shaped tool of φ33.4mm was mounted on a spindle of the EDM machine vertically to the workpiece. And the tool was rotated to make a spherical concave on the workpiece by EDM. The surface roughness of the workpiece was Rz=6.4μm and no electrode wear resulted at all. Secondly, the EDMed surface was ground with the same PCD tool. As a result, the improved surface roughness of Rz=1.7μm was obtained on the workpiece maintaining the precise tool profile and dimension.