Study On The Formation Mechanism Of Effective Abrasive In Magnetic Induction Free Abrasive Wire Sawing

Magnetic induction free abrasive wire slicing technology is a new slicing technology which is formed by adding an uniform magnetic field around the traditional saw wire.Then it is magnetized,thus leading to a high gradient magnetic field formed around it.The magnetic abrasives around the wire are adsorbed on the surface of the saw wire by the high gradient magnetic force,which increases the abrasives entering into the cutting area.Hence,the number of effective abrasives entering into the cutting area increases,thus improving the cutting efficiency of the wire saw.The effective abrasive mainly affects the cutting efficiency of the wire saw.It has a very important significance on studying the formation mechanism of effective abrasive in magnetic induction free abrasive wire sawing process.Based on the force analysis of magnetic abrasives in high gradient magnetic field,a simulation study is carried out on the movement of magnetic abrasive in COMSOL software.Firstly,the forming process of effective abrasive is visually analyzed,and the influence of the speed of slurry supply and other factors on the formation of effective abrasive is studied.Secondly,adsorption experiment is carried out to further study the influence of the speed of slurry supply and other factors on the formation of effective abrasive.Finally,wire sawing experiments are carried out to study the speed of slurry supply and other factors on the cutting efficiency.Through the simulation and experimental researches,the following conclusions are obtained:(1)The simulation results show that:the position of magnetic abrasive at different times represents the formation process of effective abrasive;the number of effective abrasive increases with the increase of magnetic field intensity,the decrease of the dynamic viscosity of the fluid,the increase of the relative permeability of the abrasives and the increase of the magnetic abrasive size.When the slurry supply position and direction are parallel to the uniform magnetic field,the abrasives absorbed by the wire surface are concentrated on one side of the saw wire,which increases the effective abrasives participated in the cutting.The number of instantaneous effective abrasive decreases with the increase of the speed of slurry supply,but the total number of effective abrasives absorbed by the saw wire first increases and then decreases in an unit time.And the number of effective abrasive is the largest at the pulp speed 12mm/s.(2)The results of adsorption experiment show that:the effective abrasive gradually increases with the decrease of the viscosity of the cutting fluid,the increase of the magnetic field strength and the increase of the magnetic abrasive size;The number of effective abrasive participated in cutting process increases when the feed position and direction are parallel to the magnetic field;the effective abrasive gradually increases and then decreases slightly with the increase of the speed of slurry supply.(3)The results of cutting experiments show that:the cutting efficiency increases gradually with the increase of magnetic field strength,and the cutting efficiency is the highest when the magnetic field strength is 9.54×104 A/m.The cutting efficiency increases firstly and then decreases with the decrease of the viscosity of the cutting fluid,and the cutting efficiency is highest when the viscosity of cutting fluid is 0.0047 Pa·s.The cutting efficiency increases with the increase of magnetic abrasive size,but the kerf also increases.The cutting efficiency increases gradually and then tends to be gentle with the increase of speed of slurry supply,and the cutting efficiency is the highest when the feed speed is 16mm/s.