Method for manufacturing diamond wire saw by extrusion-upsetting resistance welding pre-fixing bead production

Abstract

The application discloses a manufacturing method of a diamond wire saw by using extrusion-upsetting resistance welding and pre-fixing beads, and comprises the following steps: step one, cutting a steel wire rope into a certain length and placing the steel wire rope on an extruder to extrude and upset a small step; step two, threading a bead on the steel wire rope and making the bead adhere to the small step, and fixing and connecting the outer end of the bead with the steel wire rope; step three, placing the steel wire rope on the extruder and extruding and upsetting another small step L by using an extrusion head; step four, threading a spring on the steel wire rope, making the spring abut against the bead, threading another bead on the steel wire rope; step five, fixing and connecting the outer end of the another bead with the steel wire rope and ensuring that the another bead abuts against the another small step; and step six, repeating the steps three, four and five until the fixing of the beads of the whole wire saw is completed. The application can realize more firm pre-positioning of the beads, reduce the requirement for the rubber vulcanization hardness, improve the production efficiency, and improve the quality and service life of the wire saw.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of rope saw, in particular to a manufacturing method of diamond rope saw with pre-fixed beads produced by extrusion upsetting and resistance welding. BACKGROUND

[0002] A typical rope saw is composed of a steel wire rope, beads, springs and rubber, as shown in the structure Figure 2 The rope saw is commonly used for cutting hard and large objects such as mine stone, cement columns, metals, etc., especially for large stone and cement beams in construction. The beads are made of a metal base and a powder metallurgy, in which small particle multi-edge diamonds are fixed on the base. The middle part of the metal base is a cylindrical cavity, which is worn on the steel wire rope. The springs are placed between two beads, and a certain pressure is exerted on the springs by reducing the distance between the two beads. The springs are placed in a fixed position in the mold. The outer diameter of the spring is smaller than the outer diameter of the bead. The rubber is injected, and the rubber is vulcanized to a certain hardness after a certain time of heating and pressure.

[0003] Due to the cutting characteristics, the rope saw requires preliminary positioning by the spring and stable positioning after the rubber vulcanization. The rope saw has certain toughness and strength, and the service life is improved. Low hardness will cause fast wear and tear, and the positioning function cannot be achieved, so that the beads move position and the cutting function cannot be achieved. Therefore, a manufacturing method of diamond rope saw with pre-fixed beads produced by extrusion upsetting and resistance welding is proposed to solve the above problems SUMMARY

[0004] The purpose of the present application is to provide a manufacturing method of diamond rope saw with pre-fixed beads produced by extrusion upsetting and resistance welding, which solves the problems existing in the prior art, and the bead positioning is more firm, the requirement for the hardness of rubber vulcanization is reduced, the requirement for the quality of rubber is reduced, the vulcanization time or pressure is reduced, the production efficiency is improved, and the quality and service life of the rope saw are also improved.

[0005] To achieve the above purpose, the present application provides the following scheme: the present application provides a manufacturing method of diamond rope saw with pre-fixed beads produced by extrusion upsetting and resistance welding, comprising:

[0006] Step one: cut a certain length of steel wire rope and place it on an extruder. A small step is extruded by the extrusion head of the extruder;

[0007] Step two: pass a bead through the steel wire rope, and make the bead fit the small step. The end of the bead that fits the small step is the inner end, and the end of the bead that is away from the small step is the outer end. The outer end of the bead is fixedly connected with the steel wire rope;

[0008] Step three: place the steel wire rope on the extruder, and extrude another small step by the extrusion head. The distance between two adjacent small steps is L.

[0009] Step four: threading a spring on the steel wire rope, making the spring abut against the bead, threading another bead on the steel wire rope, making another bead abut against another small step, and the two beads are located at both ends of the spring;

[0010] Step five: fixedly connecting the outer end of another bead with the steel wire rope, and ensuring that another bead abuts against another small step;

[0011] Step six: repeating steps three, four and five until the fixing of the beads of the entire rope saw is completed.

[0012] Preferably, in step six, after each cycle is repeated, the steel wire rope is rotated by an angle α, and the value of α is in the range of 5°-30°, until the fixing of the beads of the entire rope saw is completed.

[0013] Preferably, in steps two and five, the outer end of the bead is fixedly connected with the steel wire rope by using resistance spot welding.

[0014] The present application has the following technical effects: the present application can realize more firm bead pre-positioning, and the effect is obviously greater than the spring pressure, so that the requirement for the rubber vulcanization hardness is reduced, the requirement for the rubber quality is reduced, the vulcanization time or pressure is reduced, the production efficiency is improved, and the rope saw quality and service life are also improved. BRIEF DESCRIPTION OF DRAWINGS

[0015] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments will be briefly introduced below. Obviously, the drawings in the following description only constitute some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor on the basis of these drawings.

[0016] Figure 1 It is a schematic diagram of the small step structure extruded on the steel wire rope of the present application;

[0017] Figure 2 It is a schematic diagram of the bead threading structure of the present application;

[0018] Figure 3 It is a schematic diagram of the repeated small step extrusion structure of the present application;

[0019] Figure 4 It is a schematic diagram of the spring threading structure of the present application;

[0020] Figure 5 It is a schematic diagram of the structure of the present application;

[0021] Wherein, 1, steel wire rope; 2, small step; 3, spring; 4, string bead; 5, extrusion head; 6, welding point. DETAILED DESCRIPTION

[0022] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0023] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the present application will be further described in detail below with reference to the drawings and specific embodiments.

[0024] Reference Figures 1-4 The present application provides a manufacturing method of diamond wire saw produced by extruding and upsetting resistance welding pre-fixed string bead 4, comprising:

[0025] Step one: cut a certain length of steel wire rope 1 and place it on the extruder, and extrude small steps 2 through the extrusion head 5 of the extruder; Reference Figure 1 .

[0026] The length of the steel wire rope is about 2 meters longer than the formal product, which is used as an auxiliary process operation.

[0027] Step two: pass a string bead 4 through the steel wire rope 1, and make the string bead 4 adhere to the small step 2, the end of the string bead 4 adhering to the small step 2 is the inner end, and the end of the string bead 4 away from the small step 2 is the outer end, and the outer end of the string bead 4 is fixedly connected with the steel wire rope 1; Reference Figure 2 .

[0028] Step three: place the steel wire rope 1 on the extruder, and extrude another small step 2 through the extrusion head 5, the distance between the two adjacent small steps 2 is L; Reference Figure 3 .

[0029] The length of L is determined by the pitch of the wire saw.

[0030] Step four: pass a spring 3 through the steel wire rope 1, make the spring 3 abut against the string bead 4, pass another string bead 4 through the steel wire rope 1, make the other string bead 4 abut against the other small step 2, and the two string beads 4 are located at the two ends of the spring 3; Reference Figure 4 .

[0031] Step five: fixedly connect the outer end of the other string bead 4 with the steel wire rope 1, and ensure that the other string bead 4 abuts against the other small step 2; Reference Figure 4 .

[0032] Step Six: Repeat Steps Three, Four, and Five until the entire wire saw bead 4 is secured.

[0033] On the wire rope 1, within a distance of length L, there are beads 4 and springs 3. The length L is the pitch of the wire saw. Steps three, four and five are repeated continuously: extruding the small step 2, inserting the spring 3, inserting the beads 4, and then fixing the beads 4 to the wire rope 1 by resistance welding after pressing them against the small step 2. This process continues until the beads 4 of the entire wire saw are fixed. The last bead 4 is fixed to the wire rope 1 after pressing it against the small step 2.

[0034] To further optimize the scheme, in step six, after each cycle, the wire rope 1 is rotated by an angle α, where the value of α ranges from 15° to 30°, until the entire wire saw bead 4 is fixed.

[0035] In further optimization of the scheme, in steps two and five, the outer end of the bead 4 is fixedly connected to the wire rope 1 by resistance welding, and there is a weld point 6 between the bead 4 and the wire rope 1.

[0036] This method enables more secure pre-positioning of the beads, which is significantly greater than the effect of spring pressure. This reduces the requirements for rubber vulcanization hardness, thereby lowering the requirements for rubber quality, reducing vulcanization time or pressure, improving production efficiency, and also improving the quality and lifespan of the wire saw.

[0037] In this invention, the beads 4 are located at the node positions, so when they are subsequently placed into the injection mold, there is no need for manual adjustment of each bead, making the process faster and more accurate, and saving injection time. A vulcanized rubber-wrapped spring 3 is also provided between adjacent beads 4, such as... Figure 5 As shown, this is the existing process, which will not be described in detail here.

[0038] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to 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 of this invention.

[0039] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A method for manufacturing diamond wire saws using extrusion upsetting resistance welding pre-fixed beads, characterized in that, include: Step 1: Cut a certain length of steel wire rope (1), place it on the extrusion machine, and extrude a small step (2) through the extrusion head (5) of the extrusion machine; Step 2: Thread a bead (4) onto the wire rope (1) and make the bead (4) fit against the small step (2). The end of the bead (4) that fits against the small step (2) is the inner end, and the end of the bead (4) that is away from the small step (2) is the outer end. Fix the outer end of the bead (4) to the wire rope (1). Step 3: Place the steel wire rope (1) on the extrusion machine and extrude another small step (2) through the extrusion head (5). The distance between two adjacent small steps (2) is L. Step 4: Insert a spring (3) into the wire rope (1) so that the spring (3) abuts against the bead (4), insert another bead (4) into the wire rope (1) so that the other bead (4) abuts against the other small step (2), and the two beads (4) are located at both ends of the spring (3); Step 5: Fix the outer end of the other bead (4) to the wire rope (1) and ensure that the other bead (4) abuts against the other small step (2); Step 6: Repeat steps 3, 4 and 5 until the entire wire saw bead (4) is fixed.

2. The method for manufacturing a diamond wire saw using extrusion upsetting resistance welding pre-fixed beads according to claim 1, characterized in that: In step six, after each cycle, the wire rope (1) is rotated by an angle α, where the value of α is in the range of 15°-30°, until the entire wire saw bead (4) is fixed.

3. The method for manufacturing a diamond wire saw using extrusion upsetting resistance welding pre-fixed beads according to claim 1, characterized in that: In steps two and five, the outer end of the bead (4) is fixedly connected to the wire rope (1) by resistance welding.

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