The Design Of Diamond Wire-saw And Study On Cutting Characteristics

Magnetic materials,silicon crystal gemstone and other similar materials are not suitable for the use of conventional machining process because of their brittleness and high surface quality requirements.These problems have been solved by using multi-wire saw in industrial production,but multi-wire saw is not suitable for sample preparing and laboratory cutting due to the complex system and high cost of muti-wire saw.In this thesis,diamond-wire cutting technology was applied to design diamond-wire saw which has the same performance as multi-wire saw.The experimental research and theoretical analysis on diamond-wire saw were carried out systematically.Works are carried out in this thesis as following:(1)The scheme research of diamond-wire saw was carried out.In view of the complexity of wire tension adjustment and control,a new technical scheme of using air spring to furnish wire tension was applied in this thesis.And through coaxial structure,the consistent of wire roll speed was solved.Moreover,the stability of the tension in the cutting process was actualized.On this basis,the mechanical design of diamond-wire saw was done.(2)The hardware design and software development of control system were carried out.Lab VIEW was used in developing graphical user interface based on Modbus protocol.Through the integration of function module,it realized the convenient operation of control.(3)The physical model and single diamond cutting depth model were built up.The maximum tension and feed force of diamond-wire were analyzed.The effects of cutting speed and feed rate on the slice surface quality were studied.(4)The cutting results of hard and brittle materials showed the coordination among the modules of control system and the feasibility of air spring in tension adjustment of diamond-wire saw.Besides,less material loss,stable cutting operation and good slice surface quality were showed in the cutting process.In this thesis,air spring was used to adjust wire tension firstly.Coaxial structure was designed to realize the speed consistent of wire roll.The convenient control was achieved through the LabVIEW.These methods and ideas were meaningful for the development of diamond-wire saw.