Development of a multiple micro diamond wheel-tools

This study presents a novel and economical compound technique that combines co-deposition with micro w-EDM for precisely developing a multiple micro diamond wheel-tools. The wheel-blank is made of diamond grit of 0-2 μm grade by electrochemical technique, in which employs a designed micro tank with ideal convection and mini porous carrier. Using a pore size of 5-10-μm in the porous carrier, a suitable interval chip-pocket of 2-3 μm on wheel-blank can generate naturally. Formation of the multiple wheel-tools is carried out via the processes of slicing, thinning and dressing simultaneously to become grinding edges array. A circuit of resistance capacitance, which provides a very short pulse and high peak, is employed as the electrical discharge power to help in achieving a very shallow and narrow discharge cavity. The thickness of each grinding edge can be machined down to 10-μm. The experimental result shows that the proposed technique is an effective method to fabricate precision micro diamond wheel-tools.