Key Technology Research Of High Precision Diamond Wire Saw Machine For Special Crystal Cutting

KDP (Potassium Dihydrogen Phosphate) and other special nonlinear opticalcrystals are widely used in the field of superpower laser and high-end medicalequipment. It is difficult to cut this crystal due to the high brittleness. Diamond wirecutting has the advantages of high cutting precision and low material loss and it alsohas advantages to solve the problem of cracking in the cutting process. This papercarried out a systematic research on the key technical issues in the development processof diamond wire cutting machine for large-caliber and high-precision KDP and otherspecial crystals and developed a large-caliber and high-precision diamond wire cuttingmachine with a maximum cutting diameter of1.2m.This paper developed a high-precision diamond cutting machine usingreciprocating consolidation abrasive diamond wire aiming at the cutting performance ofKDP and other special crystals after analyzing the advantages and disadvantages ofvarious diamond wire cutting domestic and international. Retractable cable wire storagesystem has a single tube structure with a self-winding function cable and the wirestorage capacity is up to300m; Feeding system adopts servo motor combining with ahigh-precision ball screw; The workbench has four dimensional adjustment functionand the crystal grain can be adjusted with high precision; The cutting wire can betensioned by using heavy stuff and the tensioning force can be quantitatively adjusted;Auxiliary axle system uses high-precision aerostatic bearings and other axle systemuses high-precision ball bearings, which can effectively improve cutting accuracy.This paper analyzes the cause of tension fluctuations and its impact on the qualityof the processing and cause of the vibration during the operation of single cartridge storage EDM wire. This paper does research into the guide wheel inertia and theinfluence of driving wheel rotational acceleration to the tension fluctuation. This paperestablished a corresponding mathematical model and Simulink dynamic simulationmodel. The simulation results reveal the influence rule of guide wheel inertia andcutting resistance to the cutting wire, indicating that the changes in linear accelerationof the driving wheel has a direct impact on the tension.We conducted a series of experiments on this special crystal high-precisiondiamond cutting machine. The experimental results show that the electroplateddiamond cutting wire works well with long-time cutting and the pulley made inpolyurethane encapsulated method has a good life. After cutting several kinds of crystal,the surface roughness Ra values were less than1μm, indicating that this design canachieve high-precision manufacturing.