Surface Morphology Simulation And Experiment Of Diamond Wire Saw Cutting Hard Brittle Material

Hard brittle materials are widely used in the production and scientific research because of its high strength,high hardness,high wear resistance,corrosion resistance,thermal insulation and good chemical stability.However,it has problem such as high brittleness,low plasticity and fracture toughness and difficulty in improving surface quality.Fixed diamond wire saw has become the fastest growing and most popular method of cutting hard brittle materials because it has lower cost,narrower cutting seam,lower loss in incision and lower environmental pollution.In actual processing,there could be many factors that affect the surface appearance of finished products such as the speed of wire saw,the speed of workpiece and the tension of wire saw.In this paper,we ues the progress of the reverse cutting of wire saw as background,analyze the formation of surface topography and make simulation and research.First of all,the whole working process of fixed diamond wire saw is analyzed in detail and the abrasive grains that are evenly distributed but irregular are considered to be the abrasive disk.In order to simplify the simulation,treat the grains as cone.The corrugation on the surface of finished product due to the reverse of wire saw system error is analyzed.And establish the math model and do simulation of the topography caused by the reverse of wire saw.We get the reversing cycle of wire saw by using the tangential force so we get the width of the corrugation.Use micro arc to explain the reason of surface and predict its shape.Use the material removal rate to predict the shape and depth of the corrugation.Combined with the characteristics of abrasive motion,use Matlab software to calculate and simulate the track of the abrasive grain on the saw,establish the math model of the abrasive grains in the cutting progress.Comparing the results of the simulation and experimental results,analyze the influence of the speed of wire saw and speed of workpiece.In the situation of the speed of wire saw contains,the width of corrugation will increase with the increase of the speed of workpiece.And the depth of the corrugation will increase with the increase of the speed of wire saw.Analyze the error between experiment and simulation.Those proves that the method of simulation can forecast the trend of morphology change with the machining parameters.Analyze the effect on the surface quality and morphology of finished product caused by these factors when rotating diamond wire saw is cutting the hard brittle material.Then,we resume model for multiple machining factors with the response surface method(RSM),by using the experimental data to fit the coefficient of the model,we get the concrete expression of the response function and the reliability of model is verified.By studying the effect of machining parameters on surface quality,the machining parameters are further optimized.