Experimental Research On Manufacturing Of Resin Bonded Diamond Wire Saw

Brittle material slicing mainly uses the free abrasive wire saw, however, it exists some deficiencies, such as longer sawing time, lower sawing efficiency and environmental pollution, etc. So the fixed abrasive wire saw is getting more and more attention for its good sawing quality, higher sawing efficiency, and environmental friendliness. And compared to electroplated diamond wire saw, the resin boned wire saw has advantages of simple manufacturing process, low production cost, as well as good sawing surface quality, with which is expected to get a wider range of application. But it also has some problems, such as low abrasive holding strength, poor wear resistance and heat resistance, insufficient service life. In view of the problems of resin bonded diamond wire saw, in order to improve the sawing performance and service life of the wire saw, orthogonal experiment was conducted to acquire the best components ratio of coating layer, the influence of manufacturing process on performance of wire saw was investigated, optimization schemes of manufacturing process and equipment were proposed in this paper, the main work were as follows:Coating layer’s components of resin bonded diamond wire saw were studied on the basis of theoretical research in order to improve the performance of the coating layer and the resin bonded wire saw by selecting suitable resin matrix, curing agents, toughening agents, nano particles, coupling agents, diluent and curing promoter. Coating layers with different ratio of components were prepared through the orthogonal experiment design, and resin bonded diamond wire saw were made using the coating layers. Choosing the material removal rate, wear rate, coating layer bonding force and machined surface roughness as evaluation indexes, monocrystalline silicon slicing experiments were conducted. After analysis and validation of the experimental results, components ratio of coating layer with the best comprehensive properties was acquired.On the basis of the above-mentioned coating layer, the subsequent improvement measures on the properties of resin bonded wire saw were studied. It indicated, with the increase of abrasive size, abrasive convex height in the coating layer increased, wire saw material removal rate also increased accordingly, and wire saw had a lowest wear rate at Φ30 to 40 mm; resin bonded wire saw made from coarsened core wire after dealing with the sand paper showed the wear rate was significantly reduced, of which coarsened by 400# sandpaper performed best; viscosity of coating layer was regulated through active diluents, liquidity and wettability were also improved to guarantee the uniformity of the abrasive dispersion, the optimum dosage was 10-20 wt%. Appropriate increase of pre-curing temperature can enhance coating layer’s pre-curing effect, and wire saw’s performance also got improved accordingly within the range of 160-200℃. Curing promoter could shorten the curing time, however too much content shortened applicable period, and led to a bad effect instead. Failure forms of self-made resin bonded diamond wire saw mainly included wear of coating layer and shedding of abrasive, with few peeling of coating layer.Production technology and equipment of the existing resin bonded diamond wire saw were introduced, the heat curing processing of resin bonded diamond wire saw was determined. Optimization schemes on core wire surface coarsening, coating layer applicator and coating die device were proposed.