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Development of surface roughness optimisation and prediction for the process of wire electro-discharge grinding

This work demonstrated the application of an alternative technique to produce axis-symmetric miniaturised components with higher geometrical complexity and with a surface finish four times better compared to those that could be manufactured with the commonly employed wire electro discharge grinding process. Based on the obtained results, the UK National Physical Laboratory (NPL) commissioned the fabrication of two micro styli in tungsten carbide, which were the size of a human hair. This subsequently allowed Prof Richard Leach (richard.leach@npl.co.uk) and his team at the NPL to further investigate manufacturing techniques for the production of miniaturised probes for micro Coordinate Measuring Machines.