Applicability of Thin Coated Diamond Electrode Systems for Micro Die-sinking EDM

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In this project, new wear resistant thin-coated diamond electrode systems for micro-die-sinking will be investigated, developed and applied. Significant advantages of diamond in comparison to the other typically used materials such as cemented carbide, tungsten or tungsten-copper are the non -existing material contamination by material transfer, the highest Youngs's modulus of all materials and the low density. These advantages enable the application of large-area micro-structured diamond foils and micro stick and tube electrodes. Result is the clarification of questions regarding materials science, technology and equipment. After the completion of the project, adopted process technologies for high precision micro die-sinking for relevant part materials are available. This second period of the project focusses on the manufacturing of micro stick and tube electrodes and the buildup of process knowledge regarding direct single-manufacturing and indirect replicative manufacturing of micro structured diamond foils. Technology charts will be elaborated, allowing for wear-optimal or removal-optimal parameter-combinations. The charts also allow for processes for machining steel, ceramics and cemented carbide with diamond thin coated electrodes with or without electrode oscillation.