A method for calculating wire cutting end point tension considering wire bow

Abstract

The application discloses a method for calculating wire cutting end point tension considering wire bow, which comprises the following steps: establishing a theoretical mathematical model for calculating wire cutting end point tension in a wire cutting process; bringing a material coefficient into the established theoretical mathematical model for calculating wire cutting end point tension to obtain a theoretical mathematical model for calculating wire cutting end point tension under the material coefficient; and obtaining real-time end point tension under specific settings according to the theoretical mathematical model for calculating wire cutting end point tension under the material coefficient. The method can provide an effective theoretical calculation basis for the wire cutting process, so as to select the wire cutting walking speed and the feeding speed in different wire tension processes, reduce the end point tension difference, reduce the probability of wire breakage in the cutting process and improve the cutting quality.

Description

Technical Field

[0001] This invention belongs to the field of wire cutting and relates to a method for calculating the tension at the wire cutting endpoints, taking into account the wire bow. Background Technology

[0002] In the actual cutting and processing of hard and brittle crystalline materials, wire cutting technology has become the choice of more and more manufacturers. Wire cutting can be divided into multi-wire cutting and single-wire cutting based on the number of slices produced. Based on the relationship between the abrasive and the diamond wire, it can be divided into bonded abrasive cutting and floating abrasive cutting. Since multi-wire cutting has the advantages of high slicing efficiency and the ability to cut more slices at once, it is the most common method chosen in actual factory production and processing.

[0003] Before cutting, the diamond wire is subjected to a constant tension. During the cutting process, due to the tangential cutting force, the tension at both ends of the diamond wire will be unequal. Generally, the tension is higher and the bow angle is smaller in the direction of the wire speed (tight side), while the tension is lower and the bow angle is larger in the direction away from the wire speed (slack side). If the tension difference between the two ends is too large, the cutting effect will be poor. Because the change in the bow angle causes the tension at both ends to change continuously during the cutting process, the tension on the tight side increases and the tension on the slack side decreases. After the bow angle stabilizes, the tension at both ends tends to stabilize. Therefore, it is necessary to invent a method that can effectively and conveniently calculate the tension at the wire cutting endpoints during the cutting process. Summary of the Invention

[0004] To address the aforementioned problems, the present invention provides a technical solution: a method for calculating the tension at the wire cutting endpoint considering the bow, comprising the following steps:

[0005] Establish a theoretical mathematical model for calculating the tension at the wire EDM endpoint during the wire EDM process;

[0006] Substituting the material coefficient into the established endpoint tension theoretical mathematical model, we obtain the endpoint tension theoretical mathematical model under the material coefficient.

[0007] Based on the mathematical model of the endpoint tension under the material coefficient, the real-time endpoint tension under a specific setting is obtained.

[0008] Furthermore, the mathematical model of the endpoint tension theory is expressed as follows:

[0009]

[0010] In the formula, v f Represents the feed rate, in mm / h, d m The diamond wire diameter is represented in mm, l represents the material width in mm, L represents the diamond wire span in mm, and v represents the diamond wire diameter in mm.c Represents the routing speed, in m / s, k. p This represents the Preston coefficient, with units of μm. 2 / N, F represents the linear tension in N, E represents the elastic modulus of diamond wire in MPa, and I represents the moment of inertia of diamond wire in m. 4 t is the cutting time in seconds, K1 is the normal material coefficient, K2 is the tangential material coefficient, Fn represents the normal cutting force in N, Ft represents the tangential cutting force in N, α1 is the arc angle of the tight side of the bow, α2 is the arc angle of the slack side of the bow, F1 is the tension at the tight side end in N, and F2 is the tension at the slack side end in N.

[0011] Furthermore, the specific settings are as follows: the wire tension changes while the wire speed, feed speed, and material width remain constant.

[0012] Furthermore: the material coefficients include the normal material coefficient K1, the tangential material coefficient K2, and the Preston coefficient k. p K1 = 61837, K2 = 282895, K p =4.47E-6.

[0013] Furthermore, the expressions for the tight-side arc rotation angle α1 and the loose-side arc rotation angle α2 of the bow are as follows:

[0014]

[0015] Where: α1 is the tight-side arc angle of the line bow, α2 is the loose-side arc angle of the line bow, v f Represents the feed rate, in mm / h, d m The diamond wire diameter is represented in mm; K1 is the normal material coefficient; K2 is the tangential material coefficient; l represents the material width in mm; L represents the diamond wire span in mm; v c Represents the routing speed, in m / s, k. p This represents the Preston coefficient, with units of μm. 2 / N, F represents the linear tension in N, E represents the elastic modulus of diamond wire in MPa, and I represents the moment of inertia of diamond wire in m. 4 t represents the cutting time, measured in seconds.

[0016] Furthermore: the wire saw used for cutting is a diamond abrasive coated wire saw or a steel wire saw.

[0017] A computer-readable storage medium storing a computer program, wherein when the computer program is executed, it performs a method for calculating the tension at the wire cutting endpoint considering a bow.

[0018] This invention provides a method for calculating the tension at the endpoints of wire cutting, taking into account the bow of the wire. This method can provide an effective theoretical calculation basis for the wire cutting process, so as to select the wire cutting speed and feed rate when processing with different wire tensions, thereby reducing the tension difference at the endpoints, reducing the probability of wire breakage during cutting, and improving the slice quality. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a flowchart of the method;

[0021] Figure 2 These are the original data diagrams for tight-side tension and slack-side tension;

[0022] Figure 3 This is a graph showing the tension data of the loose edge and tight edge after experimental fitting;

[0023] Figure 4 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 20N.

[0024] Figure 5 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 25N.

[0025] Figure 6 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 30N.

[0026] Figure 7 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 35N.

[0027] Figure 8 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 35N. Detailed Implementation

[0028] It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0029] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0031] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0032] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0033] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0034] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0035] Figure 1 This is a flowchart of the method;

[0036] A method for calculating the tension at the wire cutting endpoint considering the bow wire includes the following steps:

[0037] S1: Establish a theoretical mathematical model for calculating the tension at the wire EDM endpoint during the wire EDM process;

[0038] S2: Substitute the material coefficient into the established endpoint tension theoretical mathematical model to obtain the endpoint tension theoretical mathematical model under the material coefficient;

[0039] S3: Based on the mathematical model of the endpoint tension under the material coefficient, calculate the real-time endpoint tension under a specific setting using MATLAB programming.

[0040] Steps S1, S2, and S3 are executed sequentially;

[0041] The mathematical model of the endpoint tension theory is expressed as follows:

[0042]

[0043] In the formula, v f Represents the feed rate, in mm / h, d m The diamond wire diameter is represented in mm, l represents the material width in mm, L represents the diamond wire span in mm, and v represents the diamond wire diameter in mm. c Represents the routing speed, in m / s, k.p This represents the Preston coefficient, with units of μm. 2 / N, F represents the linear tension in N, E represents the elastic modulus of diamond wire in MPa, and I represents the moment of inertia of diamond wire in m. 4 t is the cutting time in seconds, K1 is the normal material coefficient, K2 is the tangential material coefficient, Fn represents the normal cutting force in N, Ft represents the tangential cutting force in N, α1 is the arc angle of the tight side of the bow, α2 is the arc angle of the slack side of the bow, F1 is the tension at the tight side end in N, and F2 is the tension at the slack side end in N.

[0044] The specific settings are: the wire tension changes, but the wire speed, feed speed, and material width remain unchanged.

[0045] The material coefficients include the normal material coefficient K1, the tangential material coefficient K2, and the Preston coefficient k. p The same material was used in the experiment, and its material parameters, such as K1, K2, and Kp, were identical. These values ​​were obtained experimentally: K1 = 61837, K2 = 282895, and K... p =4.47E-6.

[0046] During the formation of the bow, the expressions for the tight-side arc angle α1 and the loose-side arc angle α2 of the bow are as follows:

[0047]

[0048] Where: α1 is the tight-side arc angle of the line bow, α2 is the loose-side arc angle of the line bow, v f Represents the feed rate, in mm / h, d m The diamond wire diameter is represented in mm; K1 is the normal material coefficient; K2 is the tangential material coefficient; l represents the material width in mm; L represents the diamond wire span in mm; v c Represents the routing speed, in m / s, k. p This represents the Preston coefficient, with units of μm. 2 / N, F represents the linear tension in N, E represents the elastic modulus of diamond wire in MPa, and I represents the moment of inertia of diamond wire in m. 4 t represents the cutting time, measured in seconds.

[0049] Furthermore, the wire saw used for cutting is a diamond abrasive coated wire saw or a steel wire saw.

[0050] A computer-readable storage medium storing a computer program, wherein when the computer program is executed, it performs the method for calculating the tension at the wire cutting endpoint considering a bow.

[0051] Based on the wire EDM machine under specific settings, an experimental process of wire saw cutting on the wire EDM machine with different wire tensions was established. The wire saw cuts the material and obtains multiple sets of end tension experimental data. Experiments were conducted with different wire tensions. The experimental data collected were fitted into a smooth straight line using MATLAB programming and compared with the theoretical real-time end tension calculated under different settings using the same method.

[0052] Figure 2 These are the original data diagrams for tight-side tension and slack-side tension;

[0053] Figure 3 This is a graph showing the tension data of the loose edge and tight edge after experimental fitting;

[0054] Figure 4 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 20N.

[0055] Figure 5 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 25N.

[0056] Figure 6 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 30N.

[0057] Figure 7 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 35N.

[0058] Figure 8 This is a diagram showing the theoretical and experimental tension of the loose side and the tight side when the initial tension is 35N.

[0059] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for calculating the tension at the wire cutting endpoint considering the bow, characterized in that: Includes the following steps: Establish a theoretical mathematical model for calculating the tension at the wire EDM endpoint during the wire EDM process; Substituting the material coefficient into the established endpoint tension theoretical mathematical model, we obtain the endpoint tension theoretical mathematical model under the material coefficient. Based on the mathematical model of end-point tension under the material coefficient, the real-time end-point tension under a specific setting is obtained; The mathematical model of the endpoint tension theory is expressed as follows: (1) In the formula, v f Represents the feed rate, in mm / h, d m The diamond wire diameter is represented in mm, l represents the material width in mm, L represents the diamond wire span in mm, and v represents the diamond wire diameter in mm. c Represents the routing speed, in m / s, k. p This represents the Preston coefficient, with units of μm. 2 / N, F represents the linear tension in N, E represents the elastic modulus of diamond wire in MPa, and I represents the moment of inertia of diamond wire in m. 4 t is the cutting time in seconds, K1 is the normal material coefficient, K2 is the tangential material coefficient, α1 is the arc angle of the tight side of the bow, α2 is the arc angle of the slack side of the bow, F1 is the tension at the tight side end in N, and F2 is the tension at the slack side end in N. The expressions for the tight-side circular arc angle α1 and the loose-side circular arc angle α2 of the bow are as follows: （2） Where: α1 is the tight-side arc angle of the line bow, α2 is the loose-side arc angle of the line bow, v f Represents the feed rate, in mm / h, d m K1 represents the diamond wire diameter in mm, K2 is the normal material coefficient, l represents the material width in mm, L represents the diamond wire span in mm, and v represents the diamond wire diameter in mm. c Represents the routing speed, in m / s, k. p This represents the Preston coefficient, with units of μm. 2 / N, F represents the linear tension in N, E represents the elastic modulus of diamond wire in MPa, and I represents the moment of inertia of diamond wire in m. 4 t represents the cutting time, measured in seconds.

2. The method for calculating the tension at the wire cutting endpoint considering the bow, as described in claim 1, is characterized in that: The specific settings are: the wire tension changes, but the wire speed, feed speed, and material width remain unchanged.

3. The method for calculating the tension at the wire cutting endpoint considering the bow, as described in claim 1, is characterized in that: The material coefficient includes the normal material coefficient K. 1、 Tangential material coefficient K2 and Preston coefficient k p K1 = 61837, K2 = 282895, K p =4.47E-6.

4. The method for calculating the tension at the wire cutting endpoint considering the bow, as described in claim 1, is characterized in that: The wire saw used for cutting is a diamond abrasive coated wire saw or a steel wire saw.

5. A computer-readable storage medium storing a computer program, wherein, When the computer program is executed, it performs a method for calculating the tension at the wire cutting endpoint, taking into account the bow, as described in any one of claims 1-4.

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