Study On Process And Equipment Of Rapid Manufacture Electroplate Diamond Wire Saw

Along with the increasingly expended applications of the hard-brittle materials such as single crystal silicon,ceramics.The demands of its processing requirements become more and more strict.Electroplated diamond wire saw is an ideal method that solves some technical problems in cutting hard and brittle materials,especially the rare and valuable hard-brittle materials.The sand-bury-electroplated method was studied in this thesis.The thesis proposed a rapid manufacture electroplated diamond wire saw method——the endless blanket belt method for the first time,and researched on.The research contents include the electroplated method and processes,determining the optimal parameters,designing and manufacturing a sawing experimental equipment,designing a set of rapid manufacture equipment of electroplated diamond wire saw according to the optimal parameters.The matrix used piano wire by 0.3 mm in diameter,length of 300mm.The abrasive used the nature diamond abrasive produced by De Beers company.The results show that high quality diamond wire saw can be obtained with uniform abrasive distribution and good adhesion utilizing the sand-bury-electroplated method and the endless blanket belt method.But the method of sand-bury-electroplated has disadvantages of consuming much time,low productivity,and high production costs.The other method can remedy these disadvantages,and is suitable for mass production.The current density of pre-plating,tacking-on sand and thickening is 17A/dm~2, and the respective time was 1min,2min,3min using the endless blanket belt method. This method as compared with the sand-bury-electroplated method production diamond wire saw,the current density during the plating process was high nearly 10 times.It improved the efficiency greatly and reduced production period.Experiments were carried out with home-made cutting equipment on glass.The results show that saw kerf was flat,without burr and micro-cracks.The diamond wire saw with the new method can meet the requirement of cutting the hard-brittle materials. According to the optimal parameters of the endless blanket belt method producing diamond wire saw,designed a set of rapid manufacture equipment of electroplated diamond wire saw.It contents the structural design of electroplating tank,cleaning tank design,the transmission system design,the mechanism of gathering wire design and the selection of the electric-motors,etc.The whole electroplating process was carried in an electroplating tank,and the tank will be divided into three sections by clapboards.The distance ratio of pre-plating,tacking-on sand and thickening equal to its electroplating time ratio.And 250mm/min is selected as the wire speed.So we can figure out the length of the electroplating tank.A rubber wheel driven by the electric-motors was designed in order to ensure the same linear velocity of gathering wire and setting wire.And the friction force between the rubber wheel and gathering wire wheel derived the gathering wire wheel. While the endless blanket belt in the electroplating tank driven by a series of synchronous cog belt.This equipment ensure a constant linear velocity,and a electroplate diamond wire saw can be manufactured rapidly.