Design And Manufacturing Of Micro End Tool Of Poly-crystalline Diamond And Some Micro-milling Test

Design and manufacturing of micro end tool is one of the key technology of micro-milling. Micro end tool generally is manufactured from ultra hard material(tungsten carbide, poly-crystalline diamond, CBN etc). This paper concentrates on design and manufacturing of PCD micro end tools. The main content in this paper may be summarized as follows:Firstly, on the basis of structural analysis of micro end tools which have been in the recently study, general principles and specific requirements of design of micro end tools are summerized, and general steps of design and manufacturing of micro end tool are identified. Followed the steps, a variety of head structures and shank structures of micro end mills are designed. The structural static analysis and modal analysis of micro end tools is carried out by ANSYS.Secondly, on the basis of reviewing EDM mechanism and cutting mechanism of PCD composite film with WEDM, WEDM-HS experiment of PCD composite film is designed, to study the influence of voltage pulse width, voltage pulse duty ratio, peak current and maximum feed rate on surface quality and the above surface of PCD.Thirdly, the processing steps of PCD micro end mill can be divided into the following three steps: cutting of PCD composite film, welding of PCD blade and cemented carbide shank, shaping of milling edges of PCD micro end tool. The majority of study concentrates on the latter two steps. In the welding step, detailed analysis of the experimental equipment, materials and procedures are analyzed meticulously, and brazing temperature and filler metal which have a great influence on consolidation strength of high-frequency brazing are discussed. In the shaping step, a special fixture is designed, and specific steps of shaping of milling edges are determined. Though the three steps,◇-Ⅰtype andΔtype PCD micro end tools(Φ0.5-0.3mm) are manufactured. The problems which arise in the whole manufacturing process of PCD micro end mill are summerized, in order to improve the manufacturing process of PCD micro end mill.Lastly, micro milling experiment of the fine structure of typical straight slot is carried out to study milling performance of PCD micro mill which is shaped by WEDM.