A COMPARATIVE STUDY ON MICRO MACHINING OF SUPER FINE GRAIN TUNGSTEN CARBIDE BY VARIOUS MICRO PCD BALL END-MILLING TOOLS

Abstract

BL-PCD is expected to be an excellent material for a micro cutting tool because it is the hardest material in the world. Micro tools are used for the direct machining of high precision die and mold, and conventional PCD tools are often used for such precise machining in general. However, conventional PCD tools are insufficient when it comes to wear and chipping resistance. To study the unique die and mold machining application using a micro end mill made of BL-PCD, systematic experiments involving the machining of ultrafine grain tungsten carbide alloy have been conducted. In the study, tool wear and machined surface quality of tungsten alloy material have been evaluated in relation to the machining conditions and machining process parameters. The results have justified the superior performance of BL-PCD micro end mill, as compared to results obtained in the machining experiment based on a regular PCD micro end mill, which has the same tool geometry.