Study on high-efficiency processing of polycrystalline diamond by ultrasonic electro-discharge machining

• Project/Area Number: 25420063
• Research Category: Grant-in-Aid for Scientific Research (C)
• Allocation Type: Multi-year Fund
• Section: 一般
• Research Field: Production engineering/Processing studies
• Research Institution: Nippon Institute of Technology
• Principal Investigator: Ninomiya Shinichi 日本工業大学, 工学部, 准教授 (80453950)
• Project Period (FY): 2013-04-01 – 2016-03-31
• Project Status: Completed (Fiscal Year 2015)
• Budget Amount: ¥4,940,000 (Direct Cost: ¥3,800,000、Indirect Cost: ¥1,140,000); Fiscal Year 2015: ¥1,300,000 (Direct Cost: ¥1,000,000、Indirect Cost: ¥300,000); Fiscal Year 2014: ¥2,470,000 (Direct Cost: ¥1,900,000、Indirect Cost: ¥570,000); Fiscal Year 2013: ¥1,170,000 (Direct Cost: ¥900,000、Indirect Cost: ¥270,000)
• Keywords: 超音波放電加工 / 多結晶ダイヤモンド焼結体 / 形彫り放電加工 / ワイヤカット放電加工 / 加工能率 / 電極消耗率 / 放電・研削逐次加工 / 多結晶ダイヤモンド焼結体（PCD） / 特殊加工

Outline of Final Research Achievements

For a purpose to improve electric discharge machinability of PCD composed of coarse diamond particles, which has been thought to be extremely difficult to EDM, in this study, a US-EDM method to give an ultrasonic vibration to an electrode in axial direction, flexural direction and complex direction that couples axial and flexural directions was attempted. As a result, it was found that EDM efficiency could be improved to 6 times higher than a standard efficiency obtained in machining conventional PCD and the electrode wear could be reduced to 1/2 by giving vibrations to the electrode in axial direction．
Furthermore, precise groove machining could be achieved on a cemented carbide workpiece by utilizing a combined method of EDM and grinding using only a single tool, i.e. a rotary PCD disc tool acting as an electrode for EDM and as a wheel for grinding.

Research Products

• [Journal Article] Precise machining method by combining EDM and grinding with a rotary PCD segment tool for cemented carbide (2015)
  • Author(s): Fumio Koga, Shinichi Ninomiya and Kiyoshi Suzuki
  • Journal Title: Advanced Materials Research Volume: Vol.806 Pages: 446-451
  • DOI: 10.4028/www.scientific.net/amr.806.446
  • NAID: 130005486533
  • Peer Reviewed / Acknowledgement Compliant
• [Journal Article] 機械加工研究室の研究概要(機械工学科の研究活動と教育活動) (2015)
  • Author(s): 二ノ宮進一
  • Journal Title: 日本工業大学研究報告 Volume: Vol.45, No.3 Pages: 99-102
  • NAID: 120005690682
• [Journal Article] Material Properties of a New PCD Made of Boron Doped Diamond Particles (2014)
  • Author(s): W.Chen, M.Iwai, S.Ninomiya, K.Suzuki
  • Journal Title: Advanced Materials Research Volume: 1017 Pages: 154-159
  • DOI: 10.4028/www.scientific.net/amr.1017.154
  • Peer Reviewed / Open Access / Acknowledgement Compliant
• [Journal Article] Wire-EDM Properties of EC-PCD Made up of Boron Doped Diamond Particles (2014)
  • Author(s): William Chen, Shinichi Ninomiya, Shunsuke Nochi, Manabu Iwai, Kiyoshi Suzuki
  • Journal Title: Advanced Materials Research，Advances in Abrasive Technology XVII Volume: Vol.1017 Pages: 770-775
  • DOI: 10.4028/www.scientific.net/amr.1017.770
  • Peer Reviewed / Open Access / Acknowledgement Compliant
• [Journal Article] Performance of EC-PCD Made of Boron Doped Diamond as an Electrode for EDM of Cemented Carbide (2014)
  • Author(s): William Chen, Manabu Iwai, Shinichi Ninomiya, Kiyoshi Suzuki
  • Journal Title: Advanced Materials Research，Advances in Abrasive Technology XVII Volume: Vol.1017 Pages: 776-781
  • DOI: 10.4028/www.scientific.net/amr.1017.776
  • Peer Reviewed / Open Access / Acknowledgement Compliant
• [Journal Article] Effect of Ultrasonic EDM on Machinability of Coarse PCD (2013)
  • Author(s): M.Iwai S.Ninomiya Z.Zhou K.Suzuki
  • Journal Title: PCD Advanced Materials Research Volume: 797 Pages: 362-367
  • DOI: 10.4028/www.scientific.net/amr.797.362
  • Peer Reviewed
• [Presentation] 超音波放電加工による多結晶ダイヤモンド焼結体の細孔加工 (2016)
  • Author(s): 二ノ宮進一，塩島亜木斗，藍立明， 鈴木清
  • Organizer: 2016年度精密工学会春季大会学術講演会
  • Place of Presentation: 東京理科大学（千葉県・野田市）
  • Year and Date: 2016-03-15
• [Presentation] PCDの加工技術と応用 (2015)
  • Author(s): 二ノ宮進一
  • Organizer: 塑性加工学会北関東・信越支部第１回技術講演会
  • Place of Presentation: 日本工業大学（埼玉県南埼玉郡）
  • Year and Date: 2015-05-13
  • Invited
• [Presentation] PCDセグメント回転工具による超硬合金の放電研削逐次加工 (2015)
  • Author(s): 二ノ宮進一，古賀文雄，鈴木清
  • Organizer: 2015年度精密工学会春季大会学術講演会
  • Place of Presentation: 東洋大学（東京都）
  • Year and Date: 2015-03-18
• [Presentation] 導電性多結晶ダイヤモンド焼結体（EC-PCD）のワイヤカット放電加工に関する研究 (2014)
  • Author(s): 野地駿輔, 二ノ宮進一, 岩井学, ウィリアムチェン, 鈴木清
  • Organizer: 2014年度砥粒加工学会学術講演会
  • Place of Presentation: 岩手大学（岩手県）
  • Year and Date: 2014-09-13
• [Presentation] PCDの超音波放電加工における振動モードの影響
  • Author(s): 岩井学，二ノ宮進一，鈴木清
  • Organizer: 砥粒加工学会学術講演会
  • Place of Presentation: 日本大学駿河台キャンパス
• [Presentation] PCDの精密加工技術の展開
  • Author(s): 二ノ宮進一
  • Organizer: 砥粒加工学会 第50回次世代固定砥粒加工プロセス専門委員会
  • Place of Presentation: 上智大学四谷キャンパス
  • Invited
• [Presentation] PCD工具による超硬金型の精密加工と関連技術
  • Author(s): 二ノ宮進一
  • Organizer: システム制御情報学会 第16回サステイナブル・フレキシブル・オートメーション研究分科会
  • Place of Presentation: ㈱新日本テック本社（大阪）
  • Invited
• [Presentation] PCD活用技術（PCD工具とPCDワーク）
  • Author(s): 二ノ宮進一
  • Organizer: 精密工学会 第34回マイクロ生産機械システム専門委員会
  • Place of Presentation: 産業技術総合研究所 臨海副都心センター別館
  • Invited