Study On The Cutting Technology Of Endless Diamond Wire Saw

Hard and brittle materials are gradually being applied to photovoltaic,laser,instrumentation,electronic communication and other industries due to their unique performance.Nickel-cobalt alloy,Nd:YAG and other hard-brittle materials have the characteristics of high hardness,high wear resistance,high brittleness,etc.,making materials sawing difficult.In this study,the material crack depth model was established based on fractured of brittle solids,the indentation depth formula was deduced,and the solid wire saw removal model was established.A sub-surface damage model for cutting brittle material ring saws was established,which included subsection of abrasive and cutting parameters.And it provide a theoretical basis for the further development of precision sawing.Endless diamond wire saw is a new cutting process,which has high cutting speed,low cutting stress,narrow kerf and environmentally friendly,and is suitable for cutting precious hard and brittle materials.In this study,we divided the failure of wire saws into macro failures and micro failures,which can provide the basis for the selection of cutting parameters.The nickel-cobalt alloy is a typical magnetic storage element and belongs to the metal type hard and brittle material,which is widely used in military industry.In this study,a nickel-cobalt alloy bar was subjected to a precision cutting test using a endless diamond wire.The value range of the cutting process parameters was calculated according to the results of the vibration equation and the material fracture limit.Then the influence of different cutting parameters on cutting quality was obtained by orthogonal test.The tension of the silk wire has the greatest influence on the speed of the wire,and the surface roughness decreases as the tension increases.Through a series of tests,the high-precision endless diamond cutting machine was finally designed,optimized,and assembled.The overall design plan of the machine tool is determined.The diameter of the reel was determined by calculation and finite element analysis to be ?400mm.The machine tool was designed using SolidWorks engineering software.Then the natural frequency analysis and static analysis of the machine slide and column were performed using ANSYS Workbench finite element analysis software.High-precision measuring methods are used to inspect the assembly process of key processes,and the integrated precision measurement and dynamic balance testing of the cutting system are completed after assembly,and finally the machine tool assembly is completed.Orthogonal test is used to cut specific YAG crystal rods,and the influence of cutting process parameters on cutting quality is evaluated by grey correlation degree.Using the optimized cutting process parameters,the qualified crystal flakes with a surface shape accuracy of 30 ?m and a surface roughness of 0.78 ?m were finally cut out.