| The diamond bead saw is a linear cutting tool,which has been widely used in stone mining,slicing and cutting of large structural parts.The traditional diamond bead saw is easy to damage the isolation sleeve during the process of cutting the sharp corners of the workpiece,thereby affecting the cutting performance and service life of the diamond bead saw.In order to solve this problem,this subject developed a 4.3mm diameter diamond bead saw without isolation sleeve,and conducted a preliminary study on its manufacturing process.The main contents of this research include:(1)Both electroplating and brazing are applied to the preparation process of the diamond bead saw without isolation sleeve,that is,a nickel layer with a thickness of1 mm is deposited on the steel wire rope as the bead matrix by electroplating,and the diamond abrasive grains are consolidated on the bead matrix by brazing.In addition,the thermal damage caused by high-frequency induction brazing to 70# high carbon steel wire rope and 304 stainless steel wire rope was compared and analyzed through the tensile performance test and the microscopic observation of the metallographic structure.(2)The preparation process of the segmented electroplating high-frequency induction heating layer on the 304 stainless steel wire rope was studied,and the bonding strength between the high-frequency induction heating layer and the wire rope matrix was theoretically analyzed,and the scanning electron microscope and X-ray energy spectrometer(EDS)studied the bonding interface area between the high-frequency induction heating layer and the wire rope matrix.The study found that there were no cracks in the bonding interface between the bead matrix and the wire rope,and the bonding was intact.(3)The high-frequency induction heating layer brazing diamond abrasive grains was studied,and the process parameters such as heating time,coil current and coil size were optimized.In addition,with the aid of scanning electron microscopy,the alloy solder layer and the induction heating layer and the diamond bonding interface area were studied,and the elements in the bonding interface area were analyzed and line scanned by X-ray energy spectrometer(EDS).The results show that the high-frequency induction brazing of the diamond bead saw for 8s in a coil of matching size under the condition of a coil current of 600 A will have a good brazing effect.The alloy brazing material layer and the high-frequency induction heating layer are combined very well.The diamond abrasive grains are wrapped in alloy brazing filler metal,showing good wettability.In addition,the elements at the bonding interface have undergone different degrees of mutual diffusion.(4)For the first time,Ansys Maxwell electromagnetic simulation software combined with Ansys Workbench finite element analysis software was used to conduct a numerical simulation study of the electromagnetic field and temperature field coupling of the high-frequency induction heating process of the diamond bead saw.The results show that the Ni-Cr alloy solder layer reaches 1000-1100℃ after induction heating for8.2-9.1s under the condition of 600 A.The larger the coil current,the smaller the coil diameter and the faster the heating rate. |
