Optimization of EDM process parameters for PCD woodworking tools

The effects of pulse width (t_ON), peak current (I_IP), pulse gap adjustment (MA) and pulse interval (t_OFF) on the processing accuracy and efficiency of PDC were investigated. The optimum EDM process parameters were determined by orthogonal experiments as follows: t_ON 2 μs, I_IP 10 A, MA 1 times, t_OFF 4 μs, processing time 458 s. The surface roughness R_a1 of YG layer was 1.04 μm and R_a2 of PCD layer was 0.59 μm. On this basis, the effects of PIKADEN high-voltage pulse control PP and high-voltage auxiliary power supply HP on the accuracy and efficiency of electrical machining were further investigated through single factor experiments and segmentation experiments. The results show that when PP is set to 11 and HP is set to 013, i.e. 1.5 A high voltage auxiliary current is added, the optimum EDM parameters of PDC are t_ON 4 μs, I_IP 10 A, MA 1 times and t_OFF 4 μs. The shortest processing time is 130 s with high processing accuracy, which is the YG layer R_a1 1.30 μm and the PCD layer R_a2 0.56 μm after processing. Compared with the optimum technological parameters determined by orthogonal experiments, the processing accuracy is not much different, but the processing efficiency is increased by 3.5 times.