Sawing Mechanism And Experimental Research For Semi-Fixed Abrasive Wire Saw

Solar photovoltaic battery demand is great in the whole world.But the solar battery has high manufacturing cost.The main reason that the sawing cost is too high,because of the low sawing efficiency and large kerf loss.To solve these problems,we proposed semi-fixed abrasive wire sawing method.In order to improve sawing efficiency and reduce kerf loss,wire saw surface make groove and abrasive particles are embedded into the groove to realize the instant consolidation.The workpiece material removal mechanism will become scratch or plough removal,not rolling-indenting removal.In this paper,the mechanism and sawing performance of semi-fixed abrasive and free abrasive wire saw were studied.(1)We analyzed mechanism of the free abrasive wire sawing which is the mainly rolling-indenting removal.After motion state of the abrasive particle was observed and sawing experiment was analyzed,we think that the wire saw directly act on the abrasive particle and remove the material by rolling-indenting in the workpiece surface during the the free abrasive wire sawing,and is not shear stress and hydrodynamic pressure.We much more understand the mechanism of the free abrasive wire sawing.Therefore,we propose the semi-fixed abrasive sawing method which has a big advantage compare with the free abrasive wire sawing method.(2)Mechanical model of abrasive particle was built in the groove.The fixed condition was obtained.According to the model,We analysis fixed condition with the spiral angle,abrasive particle radius,workpiece hardness and wire material hardness.As the spiral angle increases,abrasive particle radius,workpiece hardness and wire material hardness decreases,abrasive particle is more easily achieved fixed condition.We observed the motion state of the abrasive particle in the cutting area.The results indicate that abrasive particle can realize the instant fixed in the groove.As the film thickness varies,the abrasive particle will fall out and become the free abrasive particle.lt's further expain that fixed abrasive particle can only realize the instant fixing,namely semi-fixed.We also observed the scratch in the bottom of kerf by semi-fixed abrasive wire saw cutting experiment.These results show that semi-fixed theory is correct.(3)According to the brittle materials principles,we built the workpiece material removal model of semi-fixed abrasive wire saw during the cutting process,and the sawing experiments verify that the model is correct.(4)We analyzed difference in sawing efficiency,surface roughness and kerf width by semi-fixed abrasive wire saw and free abrasive wire saw cutting experiment.We also analyzed effect of the sawing performance about the abrasive particle matching and sawing process condition.