硬脆材料的电镀金刚石线锯超声切割锯切力研究

Research on sawing forces during ultrasonic vibration cutting of hard and brittle materials with electroplated diamond wire saw

基于冲量理论和振动加工理论，采用叠加原理建立了电镀金刚石线锯超声切割锯切力数学模型。从理论上分析了电镀金刚石线锯施加超声振动后锯切力与普通锯切力的区别，并进行了超声振动与普通锯切力对比试验研究。结果表明：锯切力的大小随线锯往复频率的提高而降低，随侧向压力的增加而增大。通过比较发现，超声振动锯切力比普通锯切力减小20％-30％。同时，对超声振动锯切过程中单颗金刚石磨粒切削运动轨迹进行了仿真分析，进一步解释了施加超声振动后锯切力减小的原因。

Based on impulse and vibration machining theories, the mathematical model of sawing force during ultrasonic vibration cutting （UVC） with electroplated diamond wire saw was established by superposition principle. The differences between sawing force in UVC and that in conventional cutting （CC） were analyzed in theory, and the sawing forces in UVC in comparison with that in CC were studied. The results indicated that the increase of diamond wire frequency leads to the decrease of the sawing force, and the sawing force increases with the increase of the lateral pressure. It is found that the sawing force in UVC is about 20% 30% less than that in CC. Meanwhile, the cutting trace of single diamond grit in sawing process was analysed by simulation, and the reason of the decrease of the sawing force after imposing ultrasonic vibration was explained further.