A brazed diamond bead wire saw provided with cooling channels

Abstract

The present application relates to a kind of brazed diamond bead stringing rope saws of cooling channel, including bead and steel rope;Bead includes matrix, matrix inside is adapted to the joint between the setting adhesive filler and steel rope, the both ends of matrix are set as working end, diamond cutting layer is set on working end, and the diameter of middle part in matrix is less than the diameter of working end and forms cooling channel.The middle section of matrix is reduced in diameter, there are two working ends on matrix, and the cooling channel formed between two working ends, so that effect is greatly improved, it is beneficial to reduce diamond wear rate, the channel simultaneously plays the role of chip, greatly shorten the axial chip removal distance, reduce friction resistance and the wear of powder dust to binder, thereby indirectly reduce the requirement to binder density and the requirement to steel wire strength, it is beneficial to the development of small diameter of rope saw.Solve the problem that the existing brazing mode limits the small diameter development of bead and has short service life.

Description

TECHNICAL FIELD

[0001] The present application relates to a wire saw, in particular to a brazed diamond bead wire saw with cooling channels. BACKGROUND

[0002] The existing brazing technology of diamond beads has various structures, and the diamond layer is arranged on the outer circumferential surface of the base ring. The overall service life of the single-layer brazed bead wire saw is short. Nowadays, more and more various structure inlaying type (multi-layer) brazing modes are used. Since the brazing mode of the bead has strong diamond holding force but relatively poor self-sharpening, in order to improve the self-sharpening and ensure the service life, the brazing ability of holding the diamond needs to be reduced, and a thicker diamond working layer needs to be selected, which will limit the development of small diameter of the bead. Increasing the length of the bead can improve the service life, but reduces the flexibility of the wire saw, and easily causes the instantaneous bending of the bead when entering the workpiece, damages the fatigue strength of the steel wire rope, and causes the rope to break. SUMMARY

[0003] The technical problem to be solved by the present application is to provide a brazed diamond bead wire saw with cooling channels, which solves the problem of the existing brazing mode limiting the development of small diameter of the bead and short service life.

[0004] The technical solution of the present application to solve the above technical problem is as follows: a brazed diamond bead wire saw with cooling channels, characterized in that it comprises a bead and a steel rope; the bead comprises a base, the inside of the base is adapted to be connected with the steel rope through the setting of a glued filler, both ends of the base are working ends, a diamond cutting layer is arranged on the working end, and the diameter of the middle part of the base is smaller than the diameter of the working end to form a cooling channel.

[0005] The present application has the advantages that: the strong diamond holding force of the brazing mode is fully utilized, the high concentration is arranged on the end surface of the base, the base is much softer than the diamond layer and has a higher wear rate, so that the diamond on the outer edge surface has good cutting edge; since the diamond on the end surface is random and disordered in the radial direction, it is not possible that the diamond on the outer edge surface is in the passivation state at the same time to form a passivation grinding surface, which is beneficial to self-sharpening.

[0006] Two working ends are arranged on the front and rear end faces of the steel base respectively, and one or more layers of diamond are coated on the working end by using brazing process as a diamond cutting layer, and the embedding degree of the front and rear end diamond in the binder is greater than or equal to 100%; the middle section of the base is reduced in diameter, the base has two working ends, and the diamond layer arranged on the end face is very thin in axial thickness, so that the middle section of the base is reduced in diameter, the reduced section forms a cooling channel, and meanwhile has a chip containing effect, the axial chip removal speed is greatly improved, the diamond wear rate is reduced, the sharpness is maintained, the frictional resistance and the wear of the binder caused by the powder chip are reduced, so that the requirement for the strength of the steel wire rope is indirectly reduced, the development of the wire saw to a small diameter is facilitated, and the problems of the existing brazing mode, such as the limitation of the development of the small diameter of the string bead and the short service life, are solved.

[0007] On the basis of the above technical scheme, the application can also be improved as follows.

[0008] Further, the front end in the cutting movement direction of the wire saw is an inlet working end, and the tail part in the cutting movement direction of the wire saw is an outlet working end, and the front and rear working ends are arranged as regular polygonal bodies with the combination of edges and planes.

[0009] Further, more diamonds are ensured at the sharp corners to maintain the shape, and the edges on the inlet working end are provided with rounded corners.

[0010] Further, the number of layers of axial diamonds in the diamond cutting layer at the edges is greater than the number of layers of axial diamonds in the diamond cutting layer at the non-edges, so as to improve the wear resistance at the edges and realize the deformation resistance of the polygon.

[0011] The beneficial effects of the above further scheme are: beneficial to efficient processing.

[0012] Further, when the outlet working end is arranged as a cylindrical body, the diameter of the outlet working end is not less than the diameter of the circumscribed circle of the inlet working end. The outer edge contour of the front end cutting layer in the cutting movement direction of the wire saw is a regular polygon, and the outer edge contour of the rear end cutting layer is a circle, and the diameter of the rear end cutting layer is greater than or equal to the diameter of the circumscribed circle of the front end cutting layer.

[0013] The beneficial effects of the above further scheme are: the rear end cutting layer can optimize the surface quality of the workpiece, and can ensure that the front end cutting layer of the next string bead can work in a high pressure mode.

[0014] Further, an intermediate inlet working end is additionally arranged to better complete the cutting work, an intermediate inlet working end is arranged between the inlet working end and the outlet working end, the intermediate inlet working end is arranged as a regular polygonal body with the combination of edges and planes, and the edges of the intermediate inlet working end and the edges of the inlet working end are not on the same straight line.

[0015] Further, in order to strengthen the substrate strength, the entry working end, the exit working end and the middle entry working end on the substrate are provided with an inclined body away from the diamond working layer.

[0016] Further, the diamond cutting layer on the exit working end is covered on the rear end of the wire saw cutting movement direction.

[0017] Further, the diamond cutting layer on the exit working end is covered on the rear end of the wire saw cutting movement direction.

[0018] Further, the diamond cutting layer on the entry working end and the middle entry working end is covered on the front end of the wire saw cutting movement direction.

[0019] Further, the front end cutting layer and the rear end cutting layer can have different formula parameters, and the front end has higher impact resistance, and the diamond particle size can also be different.

[0020] The beneficial effects of the above further scheme are: 1. Improve the service life of the bead; 2. The development of small diameter of the bead. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 It is a three-dimensional diagram structure schematic diagram of the wire saw of the present application;

[0022] Figure 2 It is a front view cross-sectional diagram structure schematic diagram of the wire saw of the present application;

[0023] Figure 3 It is a three-dimensional diagram structure schematic diagram of the bead of the present application;

[0024] Figure 4 It is a side view structure schematic diagram of the bead of the present application;

[0025] Figure 5 It is a three-dimensional diagram structure schematic diagram of the bead of the present application provided with a middle entry working end;

[0026] Figure 6 It is a front view cross-sectional diagram structure schematic diagram of the bead of the present application provided with a middle entry working end;

[0027] Figure 7 It is a three-dimensional diagram structure schematic diagram of the wire saw of the present application provided with a middle entry working end

[0028] Figure 8 It is a front view cross-sectional diagram structure schematic diagram of another bead of the present application.

[0029] In the drawings, the components represented by each reference numeral are listed as follows:

[0030] 1-Beads, 101-Glue filler, 102-Diamond cutting layer, 2-Steel rope, 3-Matrix,

[0031] 301- Inclined body, 4- Inlet working end, 5- Outlet working end, 6- Intermediate inlet working end. Detailed Implementation

[0032] The principles and features of the present invention are described below. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0033] Example 1

[0034] A brazed diamond wire saw with cooling channels, such as Figures 1-4 As shown, it includes beads 1 and steel rope 2; beads 1 includes a base 3, and the base 3 is fitted with the steel rope 2 through an adhesive filler 101. The two ends of the base 3 are set as working ends, and diamond cutting layers 102 are provided on the working ends. The diameter of the middle part of the base 3 is smaller than the diameter of the working ends to form a cooling channel. Two working ends are respectively set on the front and rear ends of the steel substrate 3. One or more layers of diamond are axially coated on the working ends using a brazing process. The number of axial diamond layers in the diamond cutting layer at the edges is greater than that in the diamond cutting layer at the non-edges, so as to improve the wear resistance at the edges and achieve the polygonal anti-deformation effect. As the diamond cutting layer 102, the bonding agent has an axial encapsulation degree of ≥100% for the diamonds at the front and rear ends. The middle section of the substrate 3 is reduced in diameter, and there are two working ends on the substrate 3. The cooling channel formed between the two working ends greatly improves the effect and helps to reduce the diamond wear rate. This channel also acts as a chip collector, greatly shortening the axial chip removal distance, reducing frictional resistance and the wear of the bonding agent by the powder, thereby indirectly reducing the requirements for the density of the bonding agent (related to the holding force) and the strength requirements for the wire rope, which is conducive to the development of wire saws towards smaller diameters. This solves the problem that the existing brazing method restricts the development of the small diameter of the beads 1 and has a short service life.

[0035] For small-diameter wire saws, a single layer of diamond can be used to reduce the strength requirements of the wire rope and the breakage rate. If the wire rope strength is sufficient, axial multi-layer diamond can be used to improve the service life. In this case, it is not necessary to increase the diameter (i.e., increase the radial thickness of the diamond layer) to achieve this, and a good yield can be obtained.

[0036] Adhesive fillers can be commonly used adhesives or binders, such as rubber adhesive layers or rubber filler layers.

[0037] Rapid chip removal reduces the requirement for diamond exposure height, which allows for the selection of relatively finer diamonds. This reduces the negative effects of a single diamond in the passivated state and improves the self-sharpening property of bead 1.

[0038] The diamond participating in the work is located at the end face and has a small circumferential distance from each other, so that the part of the workpiece not cut by the diamond is in a convex state, which will be more or less mechanically crushed without cutting, greatly reducing the work amount of the diamond, and helping to improve the service life of the string bead 1 and reduce the cutting load.

[0039] Since the diamond is concentrated at the end face at the same axial position, the diamond layer has a high concentration, the circumferential distance between the diamonds is short, and the diamonds are arranged in an ordered manner to form a decomposition of the torsion force between each other, so that the influence of the rope saw circumferential rotation on the diamond falling is greatly reduced, which is conducive to reducing the overall concentration of the diamond and reducing the requirement for the density of the binder (related to the holding force), thereby achieving the effect of reducing the cutting load of the rope saw, and helping to design and manufacture a small diameter string bead 1.

[0040] Embodiment 2

[0041] In this embodiment, as shown in Figures 5-7 , an intermediate inlet working end 6 is added to better complete the cutting work. The intermediate inlet working end 6 is provided between the inlet working end 4 and the outlet working end 5 and is provided as a regular polygon body with a combination of edges and planes, and the edges of the intermediate inlet working end 6 and the edges of the inlet working end 4 are not on the same straight line.

[0042] In actual application, the string bead 1 can be designed into a required shape. As Figure 8 shown, for example, the inclined body 301 and the intermediate inlet working end 6 can be designed as required, and the inlet working end 4 and the outlet working end 5 can also be provided as regular polygons.

[0043] Embodiment 3

[0044] In this embodiment, as shown in Figure 2 and 6 , in order to strengthen the strength of the base body 3, the inlet working end 4, the outlet working end 5 and the intermediate inlet working end 6 on the base body 3 are provided with an inclined body 301 away from the diamond working layer. The outlet working end 5 is covered with a diamond cutting layer 102 at the rear end in the direction of the rope saw cutting movement. The diamond cutting layer 102 on the outlet working end 5 is provided on the inner side of the rear end face of the base body 3, so that the steel base body 3 forms a backrest, thereby reducing the requirement for the bonding force between the brazing layer and the base body 3. The inlet working end 4 and the intermediate inlet working end 6 are covered with a diamond cutting layer 102 at the front end in the direction of the rope saw cutting movement. The density of the diamond cutting layer 102 of the inlet working end 4 is greater than that of the outlet end diamond cutting layer 102. The formula parameters of the front end cutting layer and the rear end cutting layer can be different, and the front end has higher impact resistance. The diamond particle size can also be different.

[0045] Embodiment 4

[0046] The diamond beads manufactured by the existing brazing technology have single layer or inlaid (multi-layer) working layer. The bead 1 is a revolution body of a generatrix, most of which is a straight line; a small amount of which is a curved line or a straight line plus a curved line or a segmented curved line. During use, the front and rear ends of the bead 1 are connected by a straight line, and the revolution body is made along the straight line. The diameter of each point in the axial direction is smaller than that of the straight line, and during use, the space can be used for chip accommodation and water passage.

[0047] During the operation of the wire saw, the bead 1 moves axially and cuts, that is, the axial force is applied; the bead 1 feeds radially, that is, the radial force is applied; and the bead 1 is also subjected to the circumferential force due to the pre-set rotational stress. For the inlaid bead 1, the entire circumferential diamond working layer is difficult to be homogeneous and of equal thickness, so the consumption of the circumferential portion cannot be equal. Therefore, the portion that is consumed faster is closer to the axis, and is more likely to be automatically diverted for priority use, resulting in an increasing deviation and causing the bead 1 to be underutilized and fail, and the service life is greatly shortened.

[0048] During the cutting of the bead 1, the binder holding the diamond particles is quickly worn at the front and side portions of the particles, and the rear portion has a trailing effect, that is, the support is good. The diamond must have a certain protrusion height to ensure that the workpiece can be engraved, and also should have a protrusion height space to accommodate chips / water. However, the higher the protrusion height, the worse the ability to resist the circumferential tangential force that causes the diamond to fall off.

[0049] During the cutting of the bead 1, the contact section with the workpiece is in the form of a circular arc, which has a macroscopic centering effect, but it is difficult to limit the rotation of the bead 1. Although this rotation is beneficial to the balanced consumption of the bead 1 when the shape of the bead 1 is normal, it also causes the diamond to be subjected to the circumferential tangential force, which is one of the largest stress sources that cause the diamond to fall off unnecessarily and is one of the key factors that cause the service life of the bead 1 to be unnecessarily shortened.

[0050] During the cutting of the bead 1, when the bead 1 is deformed, the frequency of abnormal circumferential stress rotation is much higher than the pre-set internal stress circumferential stress of the wire saw, which also causes a large stress on the fixed structure of the bead 1 to the steel wire rope, and is one of the largest stress sources that cause the bead 1 to loosen. The loosening of the bead 1 will cause the inner diameter of the bead 1 to rub against the steel wire rope, resulting in the breaking of the wire saw, which is one of the key factors that affect the service life of the wire saw.

[0051] The existing brazing technology of diamond string bead 1, the diamond is arranged on the outer diameter circumferential surface of the base body 3 ring, has various structural shapes, the single layer brazing string bead 1 of the rope saw has short overall life; now more and more various structural shapes of the inlaid type (multi-layer) brazing mode are used, due to the brazing mode of the string bead 1, the diamond holding force is strong but the self-sharpening is relatively poor, in order to improve the self-sharpening and ensure the life, the brazing ability of holding the diamond needs to be reduced, and the thicker diamond working layer is selected, which will limit the development of the small diameter of the string bead 1; increasing the length of the string bead 1 can improve the life, but reduces the flexibility of the rope saw, and easily causes the instantaneous bending of the string bead 1 when entering the workpiece, damages the fatigue strength of the steel wire rope, and increases the rope breaking rate. The front end in the cutting movement direction of the rope saw is the inlet working end 4, and the tail in the cutting movement direction of the rope saw is the outlet working end 5, the inlet working end 4 is provided as a regular polygon body with a combination of edges and planes, and the outlet working end 5 is provided as a cylindrical body. The diameter of the outlet working end 5 is not less than the diameter of the inscribed circle of the inlet working end 4. The outer edge contour of the front end cutting layer in the cutting movement direction of the rope saw is a regular polygon, the outer edge contour of the rear end cutting layer is a circle, the diameter of the rear end cutting layer is greater than or equal to the diameter of the inscribed circle of the front end cutting layer, the rear end cutting layer can play a role in optimizing the surface quality of the workpiece, and can ensure that the front end cutting layer of the next string bead 1 can work in a high pressure mode. Ensure that more diamonds are provided at the sharp corners to maintain the shape, and the edges on the inlet working end 4 are provided with rounded corners.

[0052] When the front end cutting layer is a polygon, the string bead 1 is limited in rotation during cutting; the polygon string bead 1 rotates freely when it leaves the workpiece, so that the part used each time is in a random state, to ensure the balanced wear of the diamond working layer of the polygon string bead 1, even if the diamond working layer has been unbalanced, it will not further accelerate the imbalance, avoiding or reducing the negative impact of the tangential force on the diamond shedding, this feature provides the possibility of reducing the diamond concentration, reducing the diamond concentration can increase the diamond cutting pressure, improve the sharpness, and reduce the cost of diamond.

[0053] The polygon string bead 1, the angle of each polygon string bead 1 entering the workpiece is random, which greatly reduces the probability that the cutting surfaces of the front and rear polygon string beads 1 coincide during cutting, which reduces the contact area of the polygon string bead 1 with the workpiece during cutting, increases the pressure of the polygon string bead 1 during cutting, and is beneficial to the diamond cutting, that is, the improvement of cutting efficiency; this feature also provides space for increasing the diamond concentration, which can improve the life of the polygon string bead 1; this phenomenon also provides favorable conditions for chip removal / cooling, which is beneficial to the reduction of diamond heat loss, the maintenance of the blade angle, that is, the improvement of life and sharpness.

[0054] In addition, the arrows on figures 1, 3, 5 and 7 represent the movement direction of the rope saw during cutting.

[0055] In the description of the present application, it is to be understood that the orientations or positional relationships indicated by the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like are based on the orientations or positional relationships shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0056] In addition, the terms "first", "second", "third", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined with "first", "second", etc. can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "a plurality of" is at least two, such as two, three, etc., unless otherwise explicitly specified and limited.

[0057] In the present application, unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connecting", "fixing" and the like should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or it can be integrated; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the internal communication of two elements or the interaction relationship between two elements, unless otherwise explicitly limited. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0058] In the present application, unless otherwise explicitly specified and limited, the first feature "on" or "under" the second feature can be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, the first feature "above", "over" and "on" the second feature can be that the first feature is directly above or obliquely above the second feature, or it can only mean that the horizontal height of the first feature is higher than that of the second feature. The first feature "below", "under" and "under" the second feature can be that the first feature is directly below or obliquely below the second feature, or it can only mean that the horizontal height of the first feature is less than that of the second feature.

[0059] In the description of the specification, the description of the terms "one embodiment", "some embodiments", "an example", "a specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are contained in at least one embodiment or example of the present application. In the specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any suitable manner in any one or more embodiments or examples. In addition, the person skilled in the art can combine and combine the different embodiments or examples described in the specification and the features of the different embodiments or examples without contradiction.

[0060] Although the embodiments of the present application have been shown and described above, it is understood that the above-described embodiments are exemplary and are not to be construed as limiting the present application, and those skilled in the art can make changes, modifications, replacements and variations to the above-described embodiments within the scope of the present application.

Claims

1. A brazed diamond wire saw with a cooling channel, characterized in that, It includes a bead (1) and a steel rope (2); the bead (1) includes a base (3), the base (3) is fitted with the steel rope (2) by setting an adhesive filler (101), the two ends of the base (3) are set as working ends, the end face of the working end is provided with a diamond cutting layer (102), and the outer diameter of the middle part of the base (3) is smaller than the outer diameter of the working end, so that the middle part of the base is recessed to form an annular cooling channel. When the wire saw performs the cutting motion, the front end of the movement direction is the inlet working end (4), and the inlet working end (4) is set as a regular polygon with edges and planes combined; When the wire saw performs a cutting motion, the tail end of the direction of motion is the exit working end (5); An intermediate inlet working end (6) is provided between the inlet working end (4) and the outlet working end (5); An inclined body (301) is provided on the side away from the diamond working layer on the inlet working end (4), outlet working end (5) and intermediate inlet working end (6) of the substrate (3); The rear end of the outlet working end (5) is covered with a diamond cutting layer (102) in the direction of movement when the wire saw is cutting. The front end of the inlet working end (4) and the intermediate inlet working end (6) are covered with a diamond cutting layer (102) in the direction of movement when the wire saw is cutting.

2. A brazed diamond wire saw with a cooling channel according to claim 1, characterized in that, The outlet working end (5) is configured as a regular polygon or cylinder with edges and a plane.

3. A brazed diamond wire saw with a cooling channel according to claim 2, characterized in that, The edges of the inlet working end (4) are rounded.

4. A brazed diamond wire saw with a cooling channel according to claim 2, characterized in that, The maximum diameter of the outlet working end (5) is not less than the circumscribed circle diameter of the inlet working end (4).

5. A brazed diamond wire saw with a cooling channel according to claim 2, characterized in that, The intermediate inlet working end (6) is set as a regular polygon with edges and a plane, and the edges of the intermediate inlet working end (6) and the edges of the inlet working end (4) are not on the same straight line.

6. A brazed diamond wire saw with a cooling channel according to claim 5, characterized in that, The diamond cutting layer is also provided on one end face of the intermediate inlet working end.

7. A brazed diamond wire saw with a cooling channel according to claim 6, characterized in that, The number of axial diamond layers in the diamond cutting layer at the edge is greater than the number of axial diamond layers in the diamond cutting layer at the non-edge.

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