A study has been performed to understand the mechanism for generating a high quality surface on fine grain tungsten carbide dies and molds for miniature products by PCD micro end-milling operations. In order to find the best milling conditions, systematic experimental procedures have been introduced. The procedures include the preparation of various diameter single edge end-mills made of PCD (poly-crystalline diamond), sequential variation of machining conditions, and the precise setting of various instruments to observe the dynamic behavior during the machining process. By following the proposed procedures, optimum conditions for achieving the best machined surface quality have successfully been obtained.
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