Micro Pin Fabrication of Tungsten Carbide Using Polycrystalline Diamond

Micro tool fabrication is crucial in micro machining. Wire electro-discharge grinding (WEDG) is one of the popular methods applied to fabricate micro tools used for micro electrical discharge machining (EDM), electrochemical machining (ECM), and ultrasonic machining (USM). WEDG can machine micro tools or features regardless of workpiece hardness. In WEDG, however, the machining speed is relatively low and the discharge gap control is not easy. In this study, the micro mechanical machining using the polycrystalline diamond is introduced to fabricate the micro cylindrical tool or micro pin of the tungsten carbide. This method demonstrates the possibility of applying ductile machining of tungsten carbide without brittle fracture or cracks. This paper compared the machining characteristics such as material removal rate and surface roughness with the PCD-mechanical machining and WEDG.