21-09-2017, 11:58 AM
A new integrated process technology combining "micro-EDM" with "precision composite electro-forming" is proposed for the manufacture of micro diamond tools. First, the metal substrate is cut to 50 μm in diameter using WEDG, then the micro-diamonds with a 0-2 μm grain are "plated" on the surface of the substrate by composite electro-forming, thus becoming a tool of multi-layer micro-grinding. The thickness of the electro-formed layer is controlled up to 25 μm. Nickel and diamond form the bonder and cutter, respectively. In order to generate a good convection for the electro-forming solution, a division designed with a series of perforated holes is recommended and verified. In addition to effectively reducing the impact energy of the circulatory electro-forming solution, the dispersion of the diamond grains and the displacement of the nickel ions are markedly improved. Experimental results indicate that a good circularity of the diamond tool can be obtained by arranging the arrangement of nickel spherules on the anode. To allow the diamond grains to converge toward the cathode, to increase the opportunity for replenishment on the substrate, a miniature funnel mold is designed.