Research On Manufacturing Process And Its Performance Of The Electroplated Diamond Wire Saw

With the development of Hi-Tech science and technology and production, increasing progress of microelectronics, photoelectron, sensor technology and material technology, widely using of application of silicon crystal, hard alloy, optical glass, ceramics, semiconductor materials, granite and other hard and brittle materials, the processing requirements are also getting higher and higher.In consideration of electroplated diamond wire saw cutting has a small, neat, sawing kerf surface finishing, a high rate of material, low noise, little pollution to the environment, the cutting efficiency higher merit, it has been development rapidly in recent years, and is used more and more widely in the silicon crystal, precious stones and other fields. But the manufacture of electroplated diamond wire saw has so long preparation cycle, plating efficiency is low, high manufacturing cost that hinders the application of electroplated diamond wire saw.The methods of manufacturing electroplated diamond wire saw mainly has the sand-buried and sand-suspension. The sand-buried method manufacturing has low efficiency, long preparation cycle and complicated manufacturing equipment, and is rarely used in the actual production. At present, the manufacturing of diamond fretsaws is mainly handled with the suspension method, bur this method can be affected by many factors in producing diamond wire saw. But there are many influencing factors about make the electroplated diamond wire saw and the manufacturing process parameters are complex. Therefore,it is very important thar making electroplated diamond wire saw in sand-suspension.This paper are researching the impact on the process parameters of sanding about manufacturing electroplating diamond wire saw based on the basic theory of composite plating. The experiment are using high carbon steel wire that the diameter was0.18mm were substrate and using watt model solution were plating solution and using W30-40 diamond particles were particles which including natural diamond particles and the surface treated layer of nickel plated are manufacturing electroplated diamond wire saw. This experiments found that in the case of the remaining conditions are completely consistent, we just need to replacing diamond particles which plated nickel in surface with common diamond particles, and the speed of sanding can be increased by more than double. This method are greatly improve the production efficiency of electroplated diamond wire saw and suitable for scale industrial production.This paper are also briefly analyzed the sanding mechanism of electroplated wire saw and analyzing the reasons that which improve the sanding efficiency that use of surface coat a layer of nickel plated diamond particles to replace the ordinary particles and in this methods for reunion. As the diamond particles surface with a layer of nickel, the diamond particles by the non-conductive particles into conductive. The diamond particles change the electric field distribution after it enter into plating solution and then we using the finite element technique to simulate the distribution of electric field in the plating solution.Finally also detecting the quality of electroplated diamond wire saw in sand-suspension and had carry out the cutting experiment for the glass on the self-made cutting equipment. The results shows that the kerf curf smooth, no burr and micro cracks, and the electroplated diamond wire saw can satisfy the requirement of cutting hard brittle material in sand-suspension.