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.

Blade Segment with a 3D Lattice of Diamond Grits Fabricated via an Additive Manufacturing Process

Diamond tools with orderly arrangements of diamond grits have drawn considerable attention in the machining field owing to their outstanding advantages of high sharpness and long service life.This diamond super tool,as well as the manufacturing equipment,has been unavailable to Chinese enterprises for a long time due to patents.In this paper,a diamond blade segment with a 3D lattice of diamond grits was additively manufactured using a new type of cold pressing equipment(AME100).The equipment,designed with a rotary working platform and 16 molding stations,can be used to additively manufacture segments with diamond grits arranged in an orderly fashion,layer by layer;under this additive manufacturing process,at least 216000 pcs of diamond green segments with five orderly arranged grit layers can be produced per month.The microstructure of the segment was observed via SEM and the diamond blade fabricated using these segments was compared to other commercial cutting tools.The experimental results showed that the 3D lattice of diamond grits was formed in the green segment.The filling rate of diamond grits in the lattice could be guaranteed to be above 95%;this is much higher than the 90%filling rate of the automatic array system(ARIX).When used to cut stone,the cutting amount of the blade with segments made by AME100 is two times that of ordinary tools,with the same diamond concentration.When used to dry cut reinforced concrete,its cutting speed is 10%faster than that of ARIX.Under wet cutting conditions,its service life is twice that of ARIX.By applying the machine vision online inspection system and a special needle jig with a negative pressure system,this study developed a piece of additive manufacturing equipment for efficiently fabricating blade segments with a 3D lattice of diamond grits.

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.

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.

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.

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 ).

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.

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.

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.

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.

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.

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.

Optical properties of He^(+)-implanted and diamond blade-diced terbium gallium garnet crystal planar and ridge waveguides

Terbium gallium garnet(Tb_(3)Ga_(5)O_(12),TGG)crystal can be used to fabricate various magneto-optical devices due to its optimal Faraday effect.In this work,400-keV He^(+)ions with a fluence of 6.0×10^(16)ions/cm^(2)are irradiated into the TGG crystal for the planar waveguide formation.The precise diamond blade dicing with a rotation speed of 2×10^(4)rpm and a cutting velocity of 0.1 mm/s is performed on the He^(+)-implanted TGG planar waveguide for the ridge structure.The darkmode spectrum of the He^(+)-implanted TGG planar waveguide is measured by the prism-coupling method,thereby obtaining the relationship between the reflected light intensity and the effective refractive index.The refractive index profile of the planar waveguide is reconstructed by the reflectivity calculation method.The near-field light intensity distribution of the planar waveguide and the ridge waveguide are recorded by the end-face coupling method.The He^(+)-implanted and diamond blade-diced TGG crystal planar and ridge waveguides are promising candidates for integrated magneto-optical devices.

Study on precision dicing process of SiC wafer with diamond dicing blades

An innovative method for high-speed micro-dicing of SiC has been proposed using two types of diamond dicing blades,a resin-bonded dicing blade and a metal-bonded dicing blade.The experimental research investigated the radial wear of the dicing blade,the maximum spindle current,the surface morphology of the SiC die,the number of chips longer than 10μm,and the chipped area,which depend on the dicing process parameters such as spindle speed,feed speed,and cutting depth.The chipping fractures in the SiC had obvious brittle fracture characteristics.The performance of the metal-bonded dicing blade was inferior to that of the resin-bonded dicing blade.The cutting depth has the greatest influence on the radial wear of the dicing blade,the maximum spindle current,and the damage to the SiC wafer.The next most important parameter is the feed speed.The parameter with the least influence is the spindle speed.The main factor affecting the dicing quality is blade vibration caused by spindle vibration.The optimal SiC dicing was for a resin-bonded dicing blade with a spindle speed of 20000 rpm,a feed speed of 4 mm/s,and a cutting depth of 0.1 mm.To improve dicing quality and tool performance,spindle vibrations should be reduced.This approach may enable high-speed dicing of SiC wafers with less dicing damage.

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.

Cutting performance of saw blades with microtextured rougher and finisher sawteeth

The problems of severe sawtooth wear,harsh sawing noise,and low surface quality during the processing of circular saw blades need to be solved.To improve the cutting performance of TiC-based cermet saw blades,microtextures parallel to the cutting edge were fabricated on rough and fine sawteeth by laser machining.The cutting tests were performed on a sawing platform under lubricated conditions.Models of the sawing arc length and working sawtooth cutting force variations were developed for sawing steel pipes,and the accuracy of the sawing force model was verified experimentally.The results indicate that the variations in the sawing force are proportional to the sawing arc length.The circular saw blades with microtextures that did not penetrate the sawtooth rake face exhibited the lowest cutting force,sawing noise,and highest machined surface quality.Furthermore,the worn-out distance of the rougher and finisher sawteeth was reduced by approximately 7.4%and 44.1%,respectively,compared with conventional circular saw blades.The main failure modes of sawteeth were tip wear,rake face adhesion,and oxidative wear.In addition,the mechanism by which the textures improve the cutting and wear properties of TiC-based circular saw blades was discussed.This study provided a significant concept for enhancing the cutting performance of circular saw blades and improving the machined surface quality.

Remarkable achievements,splendid future——Celebrating the 45^(th) anniversary of synthetic diamond of China

The development of China as the world’s manufacturing house is best exemplified in the industry of diamond superabrasives.Diamond is indispensable in the creation of industrial infrastructure,including the construction of roads and building of houses.The world’s diamond was provided mainly by countries outside China in last century.However,a"great leap forward"has taken shape with rapid expansion in Chinese diamond-making capabilities from the enlargement of the equipment(cubic presses) and improvements in diamond yield and product quality in the end of last century.At the turn of this century,China outpaced the rest world combined in the total diamond output,became the largest producer in the world indubitably.In 2007,China produced nearly 4.4 billion carats,80%of the world’s diamond total output.The Chinese diamond well accepted in the world can be seen in the export statistics of China & import statistics of developed countries in this paper.For example,59%of USA imported diamonds were from China in 2007;in Japan, 40%. This report contains a survey of some main industrial sectors that use diamond superabrasives.Overall,22 tables and figures are used to portray the many facets of superabrasives,including cubic boron nitride.The report also discusses several challenges facing Chinese diamonds,such as the vast price difference between imported diamond grit produced outside China and domestic supply.This paper also presents an outlook of the future development of the Chinese superabrasives industry basing on the Chinese macroeconomics and the recent data of the end-users as well as their future development trend.The paper concludes by proposing that although remarkable achievements have been made in the past 45 years,given the fact that Chinese superabrasives industry still lags behind that from the advanced countries on a multitude of variables,further endeavor should be made to make China a super country in the superabrasives industry in the world.

Analysis of solid-liquid fluid dynamics about the characteristics of electrotyping diamond-nickel composite film

In this paper,super-thin free-standing diamond grains-nickel composite film in large area were prepared by using electrotyping method,which were used to make super-thin cutting blades.Scanning electron microscope(SEM) were used to analyse the characteristics of the film.It was found that the agitation velocity and the place of impeller strongly affected the content and uniformity of diamond grains in deposited composite film when the other parameters were the same.The best film was deposited when agitation velocity was 180-220 r/m and the impeller was placed in the lower part of the solution.The obliquity of cathode strongly affected the content of diamond grains in the film,and the content reached maximum when the obliquity was kept at 45 degree.The hanging orientation of cathode strongly affected the uniformity of the thickness of the film,and uniform films were deposited when cathode was intermissively circumrotated by 90 degree in the plane itself during deposition.The fluid field in solid-liquid stirred electrolytic solution was analysed by using Computational Fluid Dynamics(CFD).And the influences of agitation velocity, the place of impeller and the obliquity of cathode on the content of diamond grains in the film were explained.With Euler-Lagrange model,the just-suspended speed of impeller in solid-liquid stirred electrolytic tank was predicted by using Zwietering formula,the predicted speed was and it was consistent with experimental result.

Design of Bionic Saw Blade for Corn Stalk Cutting

The serrated incisors of grasshopper [Chondracris rosea rosea （De Geer）] possess an advantageous capacity for cutting plant fiber. Inspired by this special geometrical structure of incisors, bionic saw blade was designed and manufactured. MATLAB software digital image processing technology was used to obtain outer margin profile from stereomicroscope pho- tograph of the serrated incisors. The outer margin profile of incisors was fitted and expressed by six-order polynomial function. To compare the cutting capacity of bionic and traditional saw blades, the internodes of dry corn stalks were cut perpendicularly. Cutting force-deformation characteristics were obtained by universal testing machine. The results of cutting experiments show that the maximum cutting force of bionic saw blade was 128.26 N, which is 15.87% lower than 152.45 N of traditional saw blade; the average cutting force of bionic saw blade was 51.56 N, which is 28.17% less than 71.78 N of traditional saw blade. Meanwhile, the cutting energy consumption of bionic saw blade was 8.95 J, which is 12.85% less than 10.27 J of traditional saw blade. Overall, the bionic saw blade can lead to noticeable reduction of the cutting force and energy. These results will be helpful for designing cutting elements of corn stalk harvesting, biomass size reduction and other processing machinery.

木工超薄圆锯片消音缝多目标优化设计

针对超薄圆锯片消音缝设计问题,提出并实施了一种基于MATLAB/ANSYS联合仿真协同非支配排序遗传算法(NSGA-Ⅱ)的多目标优化设计方法。通过Inspire软件采用变密度法进行拓扑优化,确定消音缝的设计域。构建以消音缝位置、角度及缝宽等形状参数为设计变量,以最大变形量、最大等效应力及整体振幅最小化为目标的多目标优化模型。通过MATLAB/ANSYS联合仿真协同NSGA-Ⅱ的策略,进行模型的优化求解。结果表明:4个优化解均能有效减少锯切过程中锯片的变形和整体振幅,为决策者提供了更广泛的选择空间。研究为圆锯片消音缝的多目标优化设计问题提供了可行的解决方案。