Experimental Study On The Diamond Wire Saw Machining In Hard-brittle Material With Ultrasonic Vibration

The hard-brittle material is widely used in energy, information, manufacture, and architecture field. But low productive efficiency, bad surface integrity, rapid tools wear and high product cost hold back the wider application of hard-brittle material in modern industry.A new cutting technology of using electroplated diamond to-and-fro wire saw with ultrasonic is carried out cutting on glass and ZrO₂ ceramics. The kinematics and dynamics models are established to be analyzed. The influence of abrasive granularity, diamond wire saw to-and-fro frequency, lateral pressure and other technique parameters on cutting force and surface quality was studied.It comes to a conclusion that the tangential force of ultrasonic cutting is 20%～30% lower than the traditional cutting. The normal force is lower when the side force is below 5N, otherwise it has the trend increasing by. It can get optimum surface quality at the wire saw frequency moving back and forth of 150 rpm, at the side force of 2N, at the grain size 280^#. The surface roughness of ultrasonic cutting is Ra=0.3～0.4μm meanwhile that of traditional cutting is Ra=0.8～1.0μm. The maximal fitting error and forecast error of the model is 7.32% and 11.7% respectively. It shows that the model has fairly good accuracy of fitting and forecasting.Theoretical analysis comes to the conclusion that under identical situations, the material was removed in a brittle regime under normal cutting condition and removed in a ductile regime under ultrasonic cutting. It can be seen from the surface characteristics that compared with the same conditions except without ultrasonic vibration, the cutting surface had no obvious cutting stripes and the surface was in a mist shape. The experiment results and the theoretical analysis embody out certain compatibility.