Study On Abrasives Holding Force And Mechanical Properties Of Electroplated Diamond Wire Saw

Electroplated diamond wire saw is widely used in the field of brittle material processing due to its high cutting efficiency,low environmental pollution,low production and manufacturing costs,and the development of the industry also puts forward higher requirements for the use performance of electroplated diamond wire saw.The preparation of electroplated diamond wire saw usually uses the way of composite electroplating to consolidate the diamond abrasive on the surface of the wire saw.The material characteristics of the nickel layer largely determine the service performance and life of the electroplated diamond wire saw.In this paper,the influence of nickel coating material characteristics on the diamond abrasive holding force and mechanical properties of wire saw is studied by the method of finite element analysis.The influence of the properties of nickel coating on the abrasive holding force,the tensile and torsional mechanical properties,of electroplated diamond wire saw were analyzed.The experiments of sawing monocrystalline silicon,stretching and twisting of electroplated diamond wire saw are designed and completed.The research work is of great significance to improve the quality inspection and evaluation system of electroplated diamond wire saw.The main work of this paper is summarized as follows.The plating experiment was designed.The T9A steel plate test piece was used instead of the bus bar of electroplated diamond wire saw.The plating parameters were set according to the technological parameters of the production of 065 ?m electroplated diamond wire saw in industry.The mechanical properties of the piece were tested by the nano-indentation/scratch tester and X-ray diffractometer.The hardness,elastic modulus,residual stress of the nickel plating layer and the junction strength between the nickel plating layer and the substrate of the piece were obtained.The finite element models of diamond abrasive simplified as double cone and octahedron were established respectively.The loading of diamond abrasive during sawing was analyzed.The strain of nickel coating was 4%-8%as the critical condition to judge the falling off of diamond abrasive.The influence of the hardness of the nickel coating,the residual compressive stress and the height of the diamond abrasive on the abrasive holding force was studied.When the hardness of nickel layer is increased,the holding force of diamond abrasive is enhanced,when the residual compressive stress is increased,the holding force of diamond abrasive is weakened,and when the height of outburst height is increased,the holding force of diamond abrasive is weakened.The finite element model of electroplated diamond wire saw with diameter of 65?m and abrasive particle density of 200 pieces/mm was established.The effects of the hardness of nickel layer,residual compressive stress and the combination state with the bus bar on the tensile and torsional properties of electroplated diamond wire saw were studied.The hardness of nickel layer increased,the tensile strength of the wire saw increased,and the elongation after fracture decreased,at the same time,the torsion performance decreased.The residual stress of nickel layer increased,the tensile strength of wire saw increases,and the torsion performance decreases,when the nickel layer is separated from the bus bar,the elongation of diamond wire saw increases and the number of turns increases.The performance evaluation experiment of electroplated diamond wire saw was carried out.The abrasive shedding rate of diamond wire saw is analyzed and the results are compared with the theoretical calculation.The experimental results are in good agreement with the theoretical results.The difference between the breaking force and the number of turns of the electroplated diamond wire saw and the bus bar is recorded as ?F and ?nd respectively.Compared with the results of finite element analysis,the maximum relative errors of ?F and ?nd are 5.98%and 19.0%respectively,and the maximum error of elongation after wire saw breaking is 3.38%.