Study On Discharge Erosion Of Polycrystalline Diamond In Electrical Discharge Machining Based On Temperature Distribution

Being a non-traditional contactless machining process,Electrical Discharge Machining is deemed to be one of the best effective strategy to machine Polycrystalline Diamond(PCD),which not only omits the cutting forces but also provides a high precision,regardless of the hardness of the material.It is an electro-thermal process in which electrical energy is utilized to produce a electrical spark,and material is removed from the workpiece as a result of the thermal erosion which occurs due to the spark.PCD being super hard as well as electrically conductive is luckily a conducive material for the EDM process,considering its salient feature as well as its limitations.Even though various studies have been conducted in the past regarding EDM,not many studies have been focused to PCDs.PCD being a top choice for tool material,makes it very highly sought-after material and thus it’s machining characteristics requires a good amount of research.This work is a mix of review of past works and well as the original simulation work to reach a compatible solution.Different grades of PCDs are compared and studied based on their grain size and binder content.A thermal model is established and temperature distribution as well as stress distribution is studied.Also,material removal rate is calculated based on temperature distribution and compared with other experimental works.It is found to be very close with error less than 2%.Effects of different parameters like current,pulse on time,voltage are also studied and results are explained in order to optimize the process.