Copper Tungsten Erosion Wheels And Discs

High-Performance Copper Tungsten (W/Cu) Rotary Electrodes for PCD & PCBN Tool Erosion

Achieve superior results in the demanding process of manufacturing and resharpening Polycrystalline Diamond (PCD) and Polycrystalline Cubic Boron Nitride (PCBN) cutting tools with ZYsuperhard’s high-performance Copper Tungsten (W/Cu) Rotary Electrodes. Specifically designed as consumable electrodes for use on specialized EDM (Electrical Discharge Machining) erosion machines from leading manufacturers like Walter, Enokida, Vollmer, and Lach, these W/Cu wheels/discs provide the optimal combination of electrical conductivity, thermal conductivity, density, and wear resistance required for precise, efficient, and high-quality disc erosion machining of ultra-hard tool materials.

Why Copper Tungsten (W/Cu) is the Ideal Electrode Material for PCD/PCBN Erosion:

Our W/Cu electrodes leverage the unique synergistic properties of Tungsten and Copper composites, which are essential for effectively eroding PCD and PCBN materials via EDM:

• High Electrical Conductivity: The copper component ensures efficient and stable transfer of high-frequency electrical energy from the EDM generator to the workpiece. This results in a stable, consistent, and powerful erosion process necessary for predictable material removal.
• Excellent Thermal Conductivity: Effectively dissipates the intense heat generated at the spark gap away from both the electrode tip and, critically, the heat-sensitive PCD/PCBN workpiece material. This minimizes the risk of thermal damage, micro-cracking, or graphitization of the superhard abrasive layer.
• High Density & Fine Microstructure: The dense, homogenous structure of our premium W/Cu material ensures low electrode wear (contributing to long electrode life and process economy) and allows the electrode to maintain its precise form. This directly translates to the ability to produce superior surface finishes (low roughness) and sharp edge definitions on the eroded PCD/PCBN tool.
• Optimal Wear Resistance: The tungsten component provides high resistance to the erosive effects of the electrical discharge process, ensuring the electrode shape holds up accurately during prolonged erosion cycles.

Key Features:

• Premium W/Cu Composite Material: Manufactured from high-quality, high-density Copper Tungsten composites, ensuring consistent electrical and thermal properties, low porosity, and reliable performance.
• Versatile Electrode Shapes: Available in standard and custom electrode shapes including flat discs (e.g., 1A8, 1A1 type for surfacing/edging), cup wheels (e.g., 6A2 type for angles/clearances), bow shapes, or complex profiled electrodes to match the specific geometry of the tool being manufactured or resharpened.
• Precision Manufacturing: Electrodes are precision machined to tight tolerances for dimensions, parallelism, flatness, balance, and runout, ensuring smooth, stable rotation and accurate erosion results, especially critical for high-speed rotary EDM spindles.
• Proven Machine Compatibility: Designed for seamless integration and optimized performance on widely used PCD/PCBN EDM erosion machines, including specific models from Walter, Enokida, Vollmer, Lach, Anka, and others utilizing rotary electrode technology.

Core Applications:

The primary use of these W/Cu electrodes is rotary EDM erosion (also known as disc erosion machining or EDM grinding) for the following tasks on PCD and PCBN cutting tools:

• Manufacturing New Tools: Precisely shaping PCD or PCBN segments after brazing, creating complex cutting geometries, forming chipbreakers or specific edge preparations, and achieving final dimensional accuracy on inserts, end mills, routers, saw blades, reamers, etc.
• Resharpening & Reconditioning Worn Tools: Accurately restoring worn PCD or PCBN cutting edges to their original sharpness, profile, and geometric specifications, thereby significantly extending the usable life of these valuable superhard cutting tools.

WCu Rotary Electrodes Technical Parameters Table:

Customization:

ZYsuperhard provides both potentially standard configurations and fully customized Copper Tungsten rotary electrodes. We can manufacture electrodes to your specific requirements, including Outer Diameter, Thickness, Hole Size/Mounting Interface configuration, detailed Shape/Profile (based on drawings), and potentially the specific W/Cu material composition best suited for your machine capabilities and application goals (e.g., maximizing electrode life vs. maximizing workpiece finish).

Choose ZYsuperhard W/Cu Rotary Electrodes for stable operation, efficient erosion, superior workpiece quality, and extended electrode life when manufacturing or resharpening your critical PCD and PCBN cutting tools. Contact us to discuss your specific EDM erosion electrode requirements.