Abstract: This project is to develop a self-own, time saving and cost effective manufacturing technology to produce next generation diamond conditioner. The technology will generate the micro pyramid structure arrays of the same leveling at their tips on the PCD disk. This project includes three main tasks. (1) Study of the machining PCD by wire electrical discharge machining (Wire-EDM) using a conventional used diameter wire. The machining characteristics and better machining conditions will be investigated. (2) The approximate shape of the micro structure is machined by Wire-EDM using a large diameter wire. This is followed by finishing Wire-EDM using a small diameter wire until final micro structure is obtained. The works include study of the fishing Wire-EDM of PCD, process planning and optimization of machining conditions. (3) The desired micro structure arrays are machined by die sinking EDM using the electrode having the micro structure arrays. The copper electrode is taken first to rough machine PCD. The PCD electrode is then applied for finish machining. In this category, it is necessary to study the technology of manufacturing copper and electrode electrodes. Besides, die sinking EDM of PCD using copper electrode and PCD electrode, respectively will be investigated. In carrying out this project it is expected that the characteristics of Wire-EDM PCD will be understood more comprehensively, and hence better machining conditions can be selected. It will also provide us the basic knowledge of Wire-EDM PCD using the concept of roughing followed by finishing. In addition, the feasibility of die sinking EDM PCD can be verified. The manufacturing technology under development in this project is unique. Completion of this project would enable the cooperative company to have its own technology to manufacture the most advanced diamond conditioner in the world, and hence increases its market share. The Traditional and Nontraditional Processes Laboratory in the Department of Mechanical Engineering at Taiwan University which carries out the project also has a chance to become one of the main centers in diamond machining.
PCD diamond disk