On the creation of structured abrasive tools via multiple-pass rotary wire EDM: A geometrical model

Structured abrasive tools (SATs) are considered as one of the next-generation abrasive tool solutions due to their superior ability to transport cutting fluids into grinding zones to lower grinding temperature and therefore enable high-quality machined surfaces. There are several SAT fabrication methods including mechanical, electroplating, brazing, and laser-based methods. Mechanical methods cannot produce SATs with small-sized structures due to significant contact forces, while electroplating has poor controllability of abrasive grain allocations. Brazing requires special machines with high-precision motion control, while laser-based methods need significant efforts on laser parameter selection and optimization. With this, here, we present a multiple-pass rotary wire electrical discharge machining (MPRWEDM) method to address the aforementioned limitations. We also develop a theoretical model of the created kerf profile during the MPRWEDM so as to enable controllable fabrication of SATs. The model was experimentally validated, showing a decent relative error of 9.8%. The nonlinear multiple-pass effect was studied both analytically and experimentally. Based on MPRWEDM, not only the SAT with designed grooves but also the structured surface (having an array of pyramid geometries) generated by the SAT were successfully created, proving the great potential of MPRWEDM in controllable production of even more advanced tools.