Experimental Research On Electroplated Diamond Wire Saw

With the increasingly high requirements of hard and brittle materials processing,cutting tools become the focus of attention. Fixed abrasive diamond wire saw isrecognized as one of the best cutting tools. Compared with other manufacturingmethods, the wire saw manufacturing with electroplated method has some advantages,such as long service life, low production costs and good wear resistance. Intermittentand continuous manufacturing process of electroplated diamond wire saw is studied inthis dissertation. As for the long term use of the waste bath, if discharged directly, itcan lead to environmental pollution and a waste of heavy mental resources, so theresource recycling and handling of the waste bath is studied in this dissertation.The piano wire with120μm in diameter is used to be the matrix; the diamondabrasive with15μm in diameter is used to be the abrasive; nickel plate with purity of99.9%is used to be the anode; the bath type selects Watt-type. And materialspre-treatment processes are studied to ensure not to affect the plating.Intermittent manufacturing process of electroplated diamond wire saw uses thesuspension method. The primary and secondary factors affecting the amount of thesand are investigated and SEM is used to observe the surface morphology which theprimary factors affect. According to the experiment, the optimum conditions areobtained, which are80g/L of diamond abrasives mass concentration,2A/dm~2ofaverage cathode current density,2g/L of dispersant(CMC) mass concentration, and20minutes of plating time. Manufacturing wire saw under that condition, the amountof diamond abrasives is moderate and distributes well, and also complies with therequirements of the cutting.On the base of the suspension method and the sand-bury method, a newmanufacturing process is proposed in this thesis. The pre-plating and thickeningprocess of sand-bury method is used in this method, and the tacking-on sand processuses the suspension method which changes the single line into multi-line. Accordingto this method, a continuous manufacturing process is designed. The optimum conditions of each stage are obtained by detecting the hardness and cutting thickness.The bath condition of the whole process is240g/L of the salt (nickel sulfate)concentration,5.0of pH,45℃of the temperature; the average cathode currentdensity of pre-plating and thickening process is2A/dm~2and the electroplated time isseparately13min and26min; the tacking-on sand process uses the intermittentstirring,2.5A/dm~2of the average cathode current density,20min of electroplatedtime.As for the treatment application of the plating nickel-containing waste water, thetraditional chemical precipitation is improved in this thesis. The seven nickel sulfatewith high purity is eventually generated by nickel ion through controlling pH. Theoptimum conditions are obtained by detecting the purity of the product, which are4g/L of the anionic polyacrylamide which is the flocculant,9.2～9.9of pH,30℃ofthe temperature. Under this process conditions, the purity of the product is98%,which meets the basic requirements.