Experimental Study On Shaping Of Hard And Brittle Materials Based On Electroplated Diamond Wire Saw

Hard and brittle materials have excellent properties such as high hardness,high temperature resistance,corrosion resistance,wear resistance,light weight and good self lubrication.They have very important applications in the fields of mechatronics,aerospace,armored vehicles and other national defense.Due to the characteristics of high brittleness and high hardness of hard brittle materials,it is difficult to process hard brittle materials by conventional machining methods.Electroplated diamond wire saw cutting is a kind of special machining technology widely used in the field of hard and brittle materials processing.This machining method has the advantages of high machining accuracy,good cutting surface quality,small cutting seam,saving valuable materials,environmental protection and pollution-free,low noise in the machining process,good cutting roundness and so on.In order to study the feasibility of diamond wire saw cutting hard and brittle material circular parts,and the influence of process parameters on roundness,surface roughness,surface morphology,cutting efficiency and wire bow produced by wire saw wire in the process of cutting circular arc surface.In this paper,the WEDM machine is refitted into a single line reciprocating diamond wire saw cutting machine,the experimental device for cutting hard and brittle materials is built,and the CNC motion axis C is designed to carry out the experiment of diamond wire cutting hard and brittle materials circular parts.The roundness is mainly measured by the radial runout of the circular surface.The laser displacement sensor is used to measure the radial runout of the circular surface on line.Using single factor test method,taking the radial runout of parts as the measurement index of roundness,the radial runout of circular arc parts was collected by laser displacement sensor,the surface roughness of circular arc surface was measured by Mar roughness meter,and the surface morphology of samples was observed and photographed by SEM scanning electron microscope The cutting efficiency is expressed by calculating the angle of wire bow and the material removal area per unit time.The effects of wire speed,c-axis rotation speed,wire tension and cutting point position on the roundness,surface roughness,surface morphology,cutting efficiency and wire bow angle of diamond wire saw were studied;The feasibility of diamond wire saw forming hard and brittle materials is proved.Using orthogonal experiment method,the orthogonal experiment of three factors and four levels is designed.Taking the radial runout of the arc surface as the index to measure the roundness,the influence law of linear speed,c-axis speed and tension force on the multi index of the arc surface is studied.The results show that the roundness of cutting corundum arc surface can be improved,the surface roughness of the arc surface can be reduced,the surface roughness of the arc surface can be reduced It is the best combination of cutting process parameters to improve the cutting efficiency and reduce the wire bow in the process of diamond wire saw cutting corundum arc surface.The experiment of compensating pantograph offset distance and optimizing roundness of multiple cutting is designed.Through the experimental research of forward compensating pantograph offset distance,it is concluded that compensating pantograph offset distance can optimize roundness and improve the shape precision and dimension precision of arc parts;Through the experimental study of multiple cutting ceramic glass round,it is concluded that multiple cutting round can optimize the roundness of circular parts and improve the shape accuracy and dimension accuracy of circular parts.