Research on a New Type of Diamond Saw Plate

With the developing of stone material, diamond saw pl ate is used widely, and in order to increase cutting efficiency and life-span o f diamond saw plate, there are a lot of research jobs of segment for diamond saw plate. Layered segment for diamond saw plate is to divide single segment into s everal cutting tools by its structure, then increases rock-cutting faces. For i mpregnated man-made diamond saw plate, the bonding strength of diamonds with ma trix material has great effect on its life and service. Diamond is a kind of non metal and there is such high interface energy between diamond and common metals or alloys that diamond surface can’t be soaked by low melt-point metal or allo y. Diamonds are hold in metal matrix of working layer only mechanically, rather than bonded chemically, so the usage rate of diamonds in working layer is very l ow. Weakly impregnated method refers to covering diamonds with a thin layer of tu ngsten carbide mechanically by physical method, and chemical plating membrane re fers to coating a layer of carbide, which can react with the carbon atoms on the surface of diamond by chemical method and be soaked by matrix metal. In this pa per it analyses working mechanism and sintering process of layered segment of di amond saw plate by means of resistor hot-pressing sintering, it points out shor tages of layered structure, and raises using weakly impregnated layer instead of pure matrix layer, then overcomes the pure matrix layer slipping by pulling out diamonds earlier to improve cutting efficiency of saw plate, in the same time u ses diamond grains of chemical plating membrane proposed then preventing the hea t-hurting to diamond grains in working layer during the process of welding and sintering and improving the bonding strength of diamond with matrix, then improv ing life-span and aging of diamond saw. The theory of the design of mixed holding of diamonds by matrix of saw plate assures that chemical plating diamonds in working layer cut rock and weakly impr egnated diamonds in weakly impregnated layer make segment expose, then design a new type of layered segment for diamond saw plate.

Finite Element Analysis of Diamond Saw Blades to Prevent Steel Base Wear

The FEM analysis of stress and deformation of steel base of the special diamond saw blades are carried out.The small carbide round segments are welded on the side of blades in order to increase the side wear re sistance of blade.Comparing with conventional saw blade,the maximum stress val ues of reasonable special saw blade are reduced respectively about 17%20% 33%,and the maximum deformation values are reduced respectively about 26%22 %44.7%in thetangential(X),radial(Y)and axial(Z)direction.The stress conce ntration zone is decreased for the special structure diamond saw blade.The stru ctures of diamond saw blade with different number of hard material pellet are an alyzed and optimized.

Quantitative Analysis of the Loads Acting on the Abrasive Grits in the Diamond Sawing of Granites

An experimental study was carried out to quantitati ve ly evaluate the loads acting on the diamond grits during circular sawing of two kinds of typical granite with diamond segmented saw blade. Measurements were mad e of the horizontal and vertical force components and the consumed power in order to obtain the tangential and the normal force components. The temperatures at the diamond-granite contact zone were measured using a foil thermocouple. T he measurement, together with the net sawing power, was subsequently used to est imate the energy partition to the granite by a temperature matching technique. B ased on the energy partition values, the temperatures at individual cutting poin ts were estimated using an analytical model. SEM was used to follow the topograp hies of worn diamond segments. The average force acting on each diamond grit was found to be only 4% of the diamond compressive strength measured by a static me thod. The strength disparity of diamond grits and the random protrusion of grits beyond bond matrix should be significant factors in accounting for the wear of diamond grits. The wear of diamond grits was also found to be closely related to the high temperatures generated at individual cutting points and the pop-outs of diamonds from the bond matrix might be mainly attributed to the heat conducte d to the segments.

Influences of magnetic treatment on microstructure densification of diamond saw segments

The heated test pieces were treated with alternating magnetic field by self-made experimental facility firstly. And influences of magnetic treatment on microstructure densification of Diamond Saw Segments were studied through hardness testing, ultrasonic testing, metallurgical structure and fracture pattern analysis by comparative method. The mechanism of magnetic treatment is analyzed and discussed in the end. The results show that the hardness of test pieces after magnetized are harder than before, that HRB hardness is improved by 3.58 on average. The sound path and amplitude of echo wave both decrease in test pieces after magnetized. The relative pad value of echo wave is regularly related with the microstructure densification, what is profound to further establish the regularity studying the degree of matrices densification using ultrasonic testing. The pores become few and pore shape gradually spheroidizing with the magnetic treatment, and matrices are more homogeneous and compact than the without by metallographic microscope. The degree of matrices densification is further improved after magnetized. The average crystal grain size is finer than the without, and the reason of grain refining is that densification of diamond saw blade improved. Magnetic treatment can act as one kind of effective technique to improve the microstructure densification of diamond saw segments.

Research on Cutting Force of Ultrasonic Diamond Wire Saw

Based on impulse and vibration machining theories,a mathematical model of cutting force for the electroplated diamond ultrasonic wire saw was established using superposition principle.The differences between the cutting forces with and without ultrasonic effect were analyzed theoretically and experimentally.The results indicate that the cutting force of diamond wire increases along with the spindle speed decrease and the lateral pressure increase.The force in ultrasonic vibration cutting is about 20% to 30% less than that in conventional cutting.Also,the cutting trajectory of single diamond grit in sawing process is simulated,and the reason that the ultrasonic vibration can reduce the cutting force is explained further.

Sawing Performance Comparison of Brazed and Sintered Diamond Wires

Great attention has been paid on fabricating diamond wire by using the brazing diamond because of its strong chemical bonding strength and controllability of grits distribution. Although several serving performances of brazed diamond wire have been reported, seldom do these studies refer to its process characteristics. Sawing performances of a brazed diamond wire are investigated and compared with those of a sintered diamond wire on a wire saw machine. The surface topographies of beads selected from the two wires are micro observed before sawing. The sawing tests are carried out in constant feed rate feeding（CFF） and constant normal force feeding（CNFF）. In CFF test, sawing force, power, and the cut depths of positions on contact curve are measured. Then, coupled with the observations of beads topographies, sawing force and its ratio, relations of power against material removal rate, and contact curve linearity are compared and discussed. In CNFF test, the sawing rates of the two wires are investigated. The results indicate that the brazed wire performs with lower sawing force（less 16% of tangential force and 28% of normal force）, more energy efficiency（nearly one-fifth of sawing power is saved）, at a higher sawing rate （the rate is doubled） and with better contact curve linearity as compared with the sintered wire. This proposed research experimentally evaluates the sawing performances of brazed diamond wire from the aspect of process parameters, which can provide a basis for popularizing the brazed diamond wire.

Study on swarf when sawing granite with diamond wire

The diamond wire-sawing process was developed to cut granite in both quarries and block processing plants.In this paper,swarf was collected from different areas along the sawing arc when sawing three granites.The particle size distribution and the morphology of the swarf were investigated systematically,along with the swarf formation mechanism in sawing.Granite swarf formation was dominated by transgranular fractures based on the morphology of sawn granite chips and the analysis of sawn chip size.A long cutting arc increased the movement among the swarf,tool,and workpiece,thereby inducing a secondary fracture in the sawn chip.

Polycrystalline diamond mini-cubes for sawing applications

Diamond grits are indispensable for sawing granite or concrete.Each year about 1 000 tons of diamond grits are consumed for such purposes.In all cases,mono crystalline diamond is used.However, polycrystalline grits(polygrits) are generally better performed than mono grits as abrasives.For example,poly grits of cubic boron nitride(e.g.Borazon(?) CBN-550 of Diamond Innovations) can cut faster and they last longer than mono grits(e.g.Borazon(?) CBN-500). Polygrits of alumina(e.g.Cubitron(?) of 3M) also out perform by far glassy grits(e.g.white alumina).For diamond superabrasives,micron polygrits formed by shock waves may polish as fast as mono grits of the same size,but without causing as much scratches due to the presence of smaller sintered grains.The improved performance of poly grits is attributed to their ability to micro chipping that renews the sharp cutting corners from time to time.By contrast,mono grits tend to round off at low cutting force or macro fracture at high cutting force,so they may lose the cutting ability rapidly. For sawing granite with mesh sizes 40/50 or coarser,poly grits of diamond have not been available until recently.In this research,we have made polygrits in mini cube with sizes of 18/20,20/25,and 30/40.Turbo grinders and wire saws were made by brazing both mono grits and polygrits on steel substrates.Cutting performance on granite demonstrated that grinding speed was faster with turbo grinder,and the surface finish was smoother with wire saw for poly grits than mono ones. Polygrits and mono grits of diamond were mixed for comparison(upper left).Polygrits of mini cubes were brazed on the pearl of a wire saw(upper right).Mono diamond grits were brazed on a turbo grinder(bottom diagrams ).

Experimental Study on the Machining Technology of ZrO_2 Ceramics Using Diamond Wire Saw with Ultrasonic Vibration

The influence of different technological parameter on material remove rate and surface quality of ZrO2 ceramics is studied using the cutting machining method of electroplate diamond wire saw with ultrasonic vibration.Experimental results show that,compared with the same experiment condition without ultrasonic vibration,this cutting method has the advantages of high material remove rate,good surface quality,little brokenness and so on.

Historical developments and future prospects of saw diamond

More than 1 000 tons of saw diamond grits were consumed worldwide in 2007.Even with such a mature industry,there are still major improvements possible in developing new grits.The DiaCanTM technology with patterned diamond seeding can boost the production yield of coarse mesh diamonds（e.g. 30/40）.Moreover,the DiaMind crystals formed contain a visible core.This diamond-in-diamond architecture allows self-sharpening during sawing application.Furthermore,a revolutionary polycrystalline diamond superabrasive with cubical shape was fabricated to further increase the sawing efficiency and tool longevity.Such DiaCubeTM polygrits were made tools by brazing them on pearls of wire saws and on the surface of turbo grinders. The pros and cons of major designs of high-pressure equipment for diamond synthesis were discussed with the recommendation to combine the merits of belt apparatus and cubic press.This tooling synergism may increase diamond yield at reduced cost for massive production of saw grits. In 1997 Sung Chien-Min filed a series US patents that described the art of making patterned diamond tools with diamond grits forming an array in three dimensions.He also made the debut of the world’ s first brazing tools with patterned diamond distribution at the stone exhibition in Verona in 1998（also in Nuremberg in 1999）.The patterned diamond saws were introduced by Korean companies in 2005 with the demonstration of increased cutting speeds and prolonged tool lives.

Research on Cutting Trajectory of Electroplated Diamond Wire Saw

The cutting process of electroplated diamond wire saw was researched on the basis of impulse and vibration machining theories. The different contact states in the cutting process were analyzed by using the finite element method. It shows that the cutting stress is uniformly distributed along the direction of the workpiece width in the steady state. A mathematical equation of sawing trajectory was established by using the superposition principle and the cutting experiment of wire saw to calculate the cutting trajectory. The comparison of the theoretical trajectory with the calculated one indicates that the error is less than 15%. The research results provide a theoretic basis for optimization of the saw's cutting process parameters.

SAW filter with AIN on diamond

Diamond surface acoustic wave(SAW) has been used to boost the frequency of thin film filters made of piezoelectric materials.Many designs have been tested and with significant results,in particular,AlN on diamond(AlNoD) as the interface for transmitting Rayleigh wave was studied extensively .However,in all cases,nano crystalline or microcrystalline AlN coatings were deposited,typically by sputtering or CVD,on polycrystalline diamond film.The diamond film itself may contain nano or micro grains that are deposited by CVD.The presence of extensive grain boundaries in AlN can attenuate rapidly the propagation of Rayleigh wave.Moreover,the bonding between loose atomic packing of AlN and tight lattice of diamond is weak so much of the mechanical energy is dissipated as heat.In fact,the energy loss is much higher than energy transmitted during the resonating process.In this research,we attempted to improve the matching of atoms at the interface of AlNoD by doping AlN lattice with boron atoms.The shrinking of the lattice may allow more atoms are aligned at the interface.Moreover,a method of coupling single crystal AlN on single crystal diamond is proposed.Such a coupling can maximize the signal-to-noise ratio of the resonating AlNoD at the same time minimize the insertion loss of the SAW filter.

线锯用金刚石微粉表面化学镀镍工艺及性能研究

金刚石微粉性能是提升金刚石线锯性能的关键因素。用化学镀方法在线锯用金刚石微粉表面镀镍,通过正交试验研究金刚石粒度、次亚磷酸钠浓度、镀液pH值和镀液温度对化学镀镀层沉积速率、镀层密度、镀层耐腐蚀性能、镀层致密度等性能的影响。结果表明:M1/2、M6/12、M20/30三种不同粒度金刚石微粉,在次亚磷酸钠浓度为25~35g/L、化学镀液pH值为3~11、化学镀温度为30℃~90℃时,针对镀层沉积速率、镀层密度和镀层耐腐蚀性的最佳工艺参数不同;不同粒度的金刚石微粉在相同工艺条件下化学镀镍,金刚石微粉粒度越大,镀层越均匀致密;金刚石微粉化学镀镍各工艺参数之间相互作用,共同影响镀层性能。对于不同粒度的金刚石微粉,各因素对镀层性能的影响权重不同,因此针对不同粒度、不同镀层性能需求的金刚石微粉应采取不同的镀覆工艺参数。

锈蚀现象对金刚石圆锯片锯切稳定性的影响

针对锈蚀金刚石圆锯片锯切时出现锯切稳定性降低的问题,根据不同锈蚀程度锯片的结构参数建立模型,采用有限元法对锈蚀锯片进行模态分析,将锯切振动作为稳定性的参考指标,研究锈蚀对锯片锯切稳定性的影响,并通过实验验证理论分析的准确性。结果表明:在640~1280 Hz频率范围内锈蚀锯片的振型模态比原锯片多6阶,并且相邻固有频率差值减小了8.56%,随锈蚀程度的增加,锯片更容易出现共振现象;锯片轴孔位置处和1/3至2/3半径圆环范围的锈蚀对锯片的锯切稳定性影响较大,因此可以通过优化加工参数、减少表面缺陷的方式减小锈蚀程度,降低对锯片锯切稳定性的影响。该研究为金刚石圆锯片的实际使用和防锈工艺提供了指导依据。

塔形组合式金刚石圆盘锯能耗建模及参数优化

为准确预测塔形组合式金刚石圆盘锯在荒料锯切过程中的功率,以组合锯切系统中单锯片的单磨粒平均未变形切屑厚度为媒介,建立了锯切功率的参数模型,并对其进行修正,提出一种少样本快速预测模型,通过锯切实验测量不同参数组合下的锯切功率,采用多元线性回归方法拟合数据以获取可靠的模型系数。最后以锯切参数为优化变量,以锯切比能和锯切时间最小为优化目标建立优化模型,并采用改进粒子群算法对模型进行优化求解。试验结果表明,参数模型充分解释了各锯切参数对锯切功率的影响,能够准确预测不同锯片组合方式下的锯切功率,改进的粒子群算法有较高的优化性能,使用优化后的参数能够显著降低锯切功率。

5种规格金刚石圆锯片的行波振动分析及优化

为降低金刚石圆锯片在石材切割时产生的锯切噪声,选取常规锯片、打孔锯片、切缝锯片以及在基体上开鼻型径向槽、开孔与夹层的5种典型金刚石圆锯片,利用Workbench软件对其模态、行波振动进行分析,研究其对行波振动的影响。结果表明:直径为180和230 mm的常规锯片出现行波共振,产生强烈噪声;直径为105、115和350 mm的常规锯片不出现行波共振。直径为180和230 mm的切缝锯片δ值偏大,有效避开了行波共振;直径为115和350 mm的切缝锯片δ值偏小,其降噪效果差;而直径为105 mm的夹层锯片δ值偏大,降噪效果好。5种直径锯片采用开鼻形径向槽、雨滴孔和阻尼夹层的设计方案,其δ值分别为8.13%、7.21%、6.01%、6.39%和7.00%,可进一步避开行波共振,其降噪效果更好。

金刚石串珠绳锯切割煤层卸压增透效应研究

为探讨金刚石串珠绳锯割缝对缝槽周围煤层的卸压增透效应,首先建立基于缝槽顶板受力的两端固支梁力学模型,分析顶板梁的受力特征及缝槽顶板下沉接触底板(简称触底)特性,然后采用自行设计的物理相似模拟试验平台开展相似模拟试验,分析不同工艺参数绳锯割缝后缝槽上下方煤岩层应力、位移变化规律,基于FLAC^(3D)数值模拟和开发的煤层瓦斯渗透率计算程序,分析随割煤工作面推进缝槽周围煤岩体的应力和渗透率分布特征和周期演化规律。研究表明:绳锯割缝使缝槽周围应力重新分布,缝槽顶板随着割缝工作面的推进经过顶板悬露、顶板触底,连续缓沉3种演化形态;顶板未触底时,缝槽上下方形成“U”形卸压区,最大挠度在顶板中心位置,也是最先触底部位,顶板触底之后,缝槽中间位置出现应力恢复,减弱绳锯割缝的卸压增透效果;串珠绳锯的直径越大,顶板发生触底的极限跨度越大,缝槽触底越晚,卸压效果越好;相同割缝直径增加第2条割缝,两缝槽卸压区连成一起,卸压效果相互促进,减弱两缝作用下的应力恢复现象,增大了卸压范围;缝槽推进距离足够长时,由于顶板触底,缝槽两边的卸压增透效果更好,割缝卸压的影响范围从左到右划分为应力集中区、卸压区、应力恢复区、卸压区、应力集中区,对应的卸压区和应力恢复区都有较好的增透效果。

金刚石SAW滤波器的设计和制作

通信系统向高频的发展趋势使声表面波(SAW)滤波器技术面临着越来越多的挑战。利用传统材料制作SAW滤波器的中心频率很难达到GHz频段,因此探索在高声速材料基础上制作SAW滤波器成为一种必然趋势。基于高声速材料金刚石设计了IDT/ZnO/金刚石结构的薄膜SAW滤波器,设计了镜像阻抗连接IDT的结构参数,并采用ADS软件对该结构进行了建模仿真。然后,通过ZnO薄膜制备工艺和IDT电极制备工艺,获得了金刚石SAW滤波器样品。最后,采用RF探针台对所制得的样品进行了性能测试和数据分析。测试结果表明,在金刚石厚膜衬底上获得了频率超过1 GHz的SAW滤波器样品。

ZnO/IDT/金刚石结构SAW滤波器的设计和制作

传统材料制备的声表面波(SAW)滤波器的中心频率f大多位于较低的频段(f<500 MHz),但是无线通信频段逐渐向着高频化的方向发展,因此在SAW器件领域中引入高声速材料如金刚石以提高中心频率成为一种必然趋势。基于金刚石材料、采用ZnO/IDT/金刚石新型结构,设计了交错叉指结构和镜像阻抗连接结构的叉指换能器(IDT)参数。通过优化的工艺制备流程,获得了金刚石SAW滤波器样品。最后采用RF探针台对样品进行了性能测试和数据分析。测试结果表明制备的SAW滤波器样品的测试结果与理论值比较符合,交错叉指结构滤波器获得了很低的插损,镜像阻抗连接结构滤波器有效地提高了带外抑制度。样品IDT指宽2μm,SAW滤波器中心频率可达0.775 GHz。

超声辅助金刚石线锯复合切割技术的研究进展

硬脆材料与复合材料等高性能材料在多个领域广泛应用,其切割主要采用金刚石线锯加工技术。近年来,对切割加工质量和效率的要求不断提高,超声辅助金刚石线锯复合切割技术逐渐发展起来。超声辅助金刚石线锯复合切割技术提高了锯切效率和加工表面质量,延长了锯丝服役寿命,是未来的重要发展方向。文章从超声辅助金刚石线锯复合切割技术的加工原理、加工质量和影响因素等方面概述了该技术的研究现状,并对未来需进一步研究的问题和发展方向进行了展望。