A polygonal diamond bead string wire saw

Abstract

This invention relates to a polygonal diamond beaded wire saw, comprising beads and a wire. The inner diameter of the beads is fitted to the outer diameter of the wire. Edges are provided on the outer wall of the beads, circumferentially arranged along the central axis of the beads. By providing edges on the outer wall of the beads on the wire saw, and circumferentially arranged along the central axis of the beads, the non-circular beads are less prone to rotation within the cutting groove. This avoids the problem where a thinner diamond working layer, closer to the axis, is more easily automatically rotated and prioritized for use, leading to increasingly larger deviations, insufficient use of the beads, and wear down the thinner side of the diamond, causing bead failure and significantly shortening the lifespan of the wire saw.

Description

Technical Field

[0001] This invention relates to a wire saw, specifically a polygonal diamond beaded wire saw. Background Technology

[0002] In existing wire saws, the surface of the circular beads is arc-shaped. They experience axial movement and cutting (axial force), radial feed (radial force), and circumferential force due to pre-set rotational stress. For impregnated beads, it's difficult to achieve a uniform and consistent diamond working layer across the entire circumference. Therefore, the circumferential wear is not uniform. Areas that wear out faster, closer to the axis, are more likely to be automatically redirected for priority use, leading to increasingly larger deviations. This results in insufficient use of the beads, causing them to fail and significantly shortening their lifespan. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a polygonal diamond bead wire saw, which involves beads with edges, and solves the problem of failure and significantly shortened lifespan due to insufficient use of beads.

[0004] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: a polygonal diamond bead wire saw, comprising beads and a wire, wherein the inner diameter of the beads and the outer diameter of the wire are adapted to be connected, and the outer wall of the beads is provided with edges, which are arranged circumferentially along the central axis of the beads.

[0005] The beneficial effects of this invention are: the outer wall of the beads on the wire saw is provided with an edge, which is arranged circumferentially along the central axis of the beads. The non-circular beads are not easy to rotate in the cutting groove. This avoids the problem that the thinner diamond working layer is closer to the axis and is more easily automatically turned to be used first, resulting in an increasingly large deviation, insufficient use of the beads, wear-off of the thinner diamond side, and failure of the beads, which leads to a significant reduction in the life of the wire saw.

[0006] Based on the above technical solution, the present invention can be further improved as follows.

[0007] Furthermore, the beads include a cylindrical base, an outer diamond working layer for cutting, an inner adhesive filler layer adapted to the string, and edges disposed on the diamond working layer.

[0008] Furthermore, the more edges are set, the less impact the polygonal beads will have when entering the workpiece; at least four edges should be set.

[0009] Furthermore, to ensure that the parts used each time are in a random state during the cutting process, the wear of the polygonal beaded diamond working layer is uniform, and the edges are evenly distributed circumferentially along the central axis of the beads.

[0010] Furthermore, to prevent the diamond from being broken instantly by excessive impact, chamfers are provided at the edges. The chamfers are rounded.

[0011] Furthermore, in order to ensure the strength of the diamond working layer and to ensure that the beads do not rotate as much as possible when the wire saw is working, the edges are connected by connecting surfaces.

[0012] Furthermore, to ensure that more diamonds are used to maintain the shape at the sharp corners, the edges of the beads are rounded.

[0013] Furthermore, to ensure the shape of the polygon is maintained, anti-deformation techniques are employed, such as ensuring that the solid axial length of the diamond working layer at the corners is greater than the solid axial length at the edge-connecting surface, and that the ratio of their lengths is not less than the circumcircle diameter of the polygon / the incircle diameter of the polygon.

[0014] Furthermore, the edges are set parallel to the central axis of the beads.

[0015] Furthermore, in order to reduce the impact and vibration of the polygonal beads when they first enter the workpiece, the beads are provided with an inlet end along the axial direction of the beads, and the cross-sectional area of ​​the inlet end is smaller than that of the other end.

[0016] The beneficial effects of adopting the above-mentioned further solutions are:

[0017] 1. The polygonal beads limit the rotation range, so that the part used each time is in a random state, in order to ensure the uniform wear of the diamond working layer around the polygonal beads. Even if the wear of the diamond working layer around the surface is already unbalanced, it will not accelerate further imbalance, thus avoiding or reducing the negative impact of circumferential tangential force on diamond falling off.

[0018] 2. Polygonal beads: The angle at which each polygonal bead enters the workpiece is random, resulting in a high probability that the cutting surfaces of the front and rear polygonal beads will not coincide during cutting. This reduces the contact area between the polygonal beads and the workpiece during cutting and increases the pressure during cutting. This is beneficial for the extraction of diamond from the part of the wire saw that is in contact with the workpiece, thus improving cutting efficiency. The above characteristics also help to increase the diamond concentration, thereby increasing the life of the wire saw.

[0019] 3. The cutting surfaces of polygonal beads are highly unlikely to overlap, and the resulting gaps are beneficial for cooling / chip removal, which in turn helps reduce diamond heat loss, maintain the cutting angle, and reduce the processing load. These characteristics allow for the selection of smaller diameter wire ropes and smaller bead diameters, resulting in smaller kerfs in wire sawing and improved yield. Due to the smaller load, it is more suitable for use on multi-saw machines.

[0020] 4. The rotation of the polygonal beads is restricted by the edges as they enter the workpiece, which greatly reduces the circumferential tangential force of the diamond and significantly reduces the proportion of diamonds falling out.

[0021] 5. The reduction in processing load and circumferential tangential force reduces the requirement for the binder to hold the diamond, which in turn reduces the density requirement. This will facilitate the use of pressureless sintering powder metallurgy processing technology, which has a lower manufacturing cost. Attached Figure Description

[0022] Figure 1 This is a three-dimensional structural schematic diagram of the wire saw of the present invention;

[0023] Figure 2 This is a schematic diagram of the front view of the wire saw of the present invention;

[0024] Figure 3 This is a schematic diagram of the cross-sectional structure of the wire saw of the present invention;

[0025] Figure 4 This is a cross-sectional view of the front view of the wire saw of the present invention, which is a structural schematic diagram.

[0026] Figure 5 This is a schematic diagram of the wire saw of the present invention during processing within a workpiece;

[0027] Figure 6 This is a three-dimensional structural schematic diagram of the wire saw of the present invention during processing within the workpiece;

[0028] Figure 7 This is a three-dimensional structural diagram of the present invention, showing that the beads are regular hexagonal and have an inlet end.

[0029] The attached diagram lists the components represented by each number as follows:

[0030] 1-Beads, 101-Edge, 102-Diamond working layer, 103-Glue filler layer, 104-Matrix, 105-Connecting surface, 2-String, 3-Processed part, 4-Inlet end. Detailed Implementation

[0031] 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.

[0032] Example 1

[0033] A polygonal diamond beaded wire saw, such as Figure 1-6As shown, the device includes a beaded string 1 and a string 2. The inner diameter of the beaded string 1 and the outer diameter of the string 2 are fitted together. An edge 101 is provided on the outer wall of the beaded string 1, and the edge 101 is arranged circumferentially along the central axis of the beaded string 1. The beaded string 1 includes a cylindrical base 104. A diamond working layer 102 for cutting is provided on the outside of the cylindrical base 104. An adhesive filler layer 103 adapted to the string 2 is provided inside the cylindrical base 104. The edge 101 is provided on the diamond working layer 102.

[0034] The existing product, diamond beads 1, is the core component used for cutting on a wire saw. It is generally manufactured using metal powder and powder metallurgy technology, and is an impregnated working layer. Some are also manufactured using brazing or electroforming techniques, and can be single-layered or impregnated working layers. Bead 1 is a body of revolution along a single generatrix, with most of the generatrix being straight lines; a small number are curved lines, or a combination of straight lines and curves, or a body of revolution with segmented curves. During use, the front and rear ends of bead 1 are connected by a straight line and an imaginary line. Using this line as the body of revolution, the diameters at each axial point are smaller than the diameter of the connecting line. During use, these points essentially do not perform cutting work, but can serve as spaces for chip collection and water flow.

[0035] In existing wire saw products, the beads 1 move axially and cut simultaneously (i.e., axial force), feed radially (i.e., radial force), and are also subjected to circumferential force due to pre-set rotational stress. For impregnated beads 1, it is difficult to achieve uniformity and thickness of the entire circumferential diamond working layer 102. Therefore, the circumferential wear is not uniform. The parts that wear out faster are closer to the axis and are more likely to be automatically rotated for priority use, resulting in a larger and larger deviation. This leads to insufficient use of beads 1 and failure, significantly shortening their lifespan.

[0036] In the existing technology product bead 1, the binder holding the diamond particles wears out quickly at the front and sides of the particles during cutting, while the rear has a trailing effect, i.e., better support. The diamond must have a certain exposed height to ensure that it can cut the workpiece. At the same time, it should also have exposed height space to accommodate chips / water. However, the higher the exposed height, the worse its ability to resist the damage caused by circumferential tangential forces to the diamond falling off.

[0037] When the existing product bead 1 is cutting, the contact section with the workpiece is arc-shaped, which has a macroscopic centering effect. However, it is difficult to restrict the rotation of bead 1. Although this rotation is beneficial to the balanced consumption of bead 1 when the bead 1 is in a normal shape, it also causes the diamond to be subjected to circumferential tangential force. This is one of the biggest stress sources that causes diamond to fall off unnecessarily and is one of the key factors that cause the life of bead 1 to be shortened unnecessarily.

[0038] This application provides edges 101 on the outer wall of the beads 1 on the wire saw. The edges 101 are arranged circumferentially along the central axis of the beads 1. The non-circular beads 1 are not easily rotated in the cutting groove, avoiding the problem that the thinner diamond working layer 102, closer to the axis, is more easily automatically rotated and used preferentially, leading to an increasing deviation and insufficient use of the beads 1, wear away the thinner side of the diamond, causing the beads 1 to fail and significantly shortening the life of the wire saw. To ensure that the parts used each time are in a random state during cutting, the wear of the circumferential surface of the diamond working layer 102 of the polygonal beads 1 is uniform, and the edges 101 are evenly arranged circumferentially along the central axis of the beads 1. To ensure the strength of the diamond working layer 102 and to ensure that the beads 1 do not rotate as much as possible during wire saw operation, the edges 101 are connected by a connecting surface 105. The connecting surface 105 can be a plane or a curved surface, with a plane being preferred.

[0039] Example 2

[0040] In this embodiment, the more edges 101 are provided, the less impact the polygonal bead 1 will have when entering the workpiece. At least four edges 101 are provided. The aforementioned polygon refers to a regular polygon, and the diameter of the circumscribed circle must be the required diameter. The number of sides = n + 4 (n is a natural number). The higher the linear velocity, the larger the value of n, which reduces the impact of the polygonal bead 1 entering the workpiece. When n is infinitely large, a quasi-curve will be formed. Quasi-curves have the least impact, but due to rolling issues, the diamond working layer 102 will be used unevenly, shortening the lifespan of the bead 1.

[0041] In existing products, the beads 1 cannot be perfectly aligned when entering the working position. If the diameters of the front and rear beads 1 are different, the position, proportion, and force of the contact surface of the rear bead 1 when entering the workpiece will vary, resulting in significant differences in the utilization rate of each bead 1 on the same wire saw, indirectly reducing the service life of the wire saw. In the polygonal beads 1 of this application, the angle at which each polygonal bead 1 enters the workpiece is random, resulting in a high probability that the cutting surfaces of the front and rear polygonal beads 1 will not coincide during cutting. All beads 1 will be utilized, and the grooves cut by the front and rear beads 1, as well as the tiny protrusions in the grooves, will be mechanically crushed, thereby reducing the wear of the diamond working layer and effectively improving the service life of the wire saw. In addition, reducing the contact area between the polygonal bead 1 and the workpiece during cutting increases the pressure during cutting, which is beneficial for diamond extraction, i.e., improving cutting efficiency. This feature also provides room for increasing the diamond concentration, which can improve the lifespan of the polygonal bead 1. The higher the concentration of the diamond working layer 102, the longer the bead 1 can be used, and the longer the wire saw's lifespan.

[0042] Compared to traditional beads that completely block the gap, the beads of this invention leave more gaps during processing for chip removal / cooling, which is beneficial for reducing diamond heat loss and maintaining the cutting edge, i.e. improving lifespan and sharpness.

[0043] Because the circumferential tangential force of diamond is greatly reduced, the proportion of unnecessary diamond shedding is significantly reduced. This gives the polygonal beads 1 manufactured by the pressureless sintering process the opportunity to have performance close to that of the existing hot-pressed sintered beads 1, and also gives them a cost advantage. After further research on the compatibility of the binder formulation and the diamond concentration, it is expected to significantly surpass the beads 1 manufactured by the existing hot-pressed sintering process in terms of cost performance.

[0044] Once the polygonal bead 1 is cut, its rotation is restricted by the edges and corners, which greatly reduces the circumferential tangential force of the diamond and significantly reduces the proportion of unnecessary diamond loss. This feature makes it possible to reduce the diamond concentration. Reducing the diamond concentration can increase the diamond cutting pressure, improve the sharpness, and reduce the cost of diamond.

[0045] Example 3

[0046] like Figure 3 and 5 As shown, to prevent the diamond from being broken instantly due to excessive impact, a chamfer is provided at the edge 101. The chamfer is set as a rounded corner. To ensure that more diamonds are retained at the sharp corners, the edge of the bead 1 is rounded. The intersection of the edges of the outer peripheral surface of the polygonal bead 1 is achieved by the edge and the arc being tangent, and the radius of the arc R is greater than or equal to 3 * diamond particle size, ensuring that more diamonds are retained at the sharp corners. The rounded corners at the edges and ends ensure a smooth transition when the diamond working surface is cut, preventing direct collision with the hard workpiece 3, which could cause the diamond working layer 102 to break directly or the end to fall off.

[0047] In this embodiment, the edge 101 is arranged parallel to the central axis of the bead 1. This parallel arrangement makes it easier to process the bead 1 itself.

[0048] Example 3

[0049] In this embodiment, as Figure 7As shown, taking a regular hexagonal bead 1 as an example, in order to reduce the impact and vibration of the polygonal bead 1 when it initially enters the workpiece, the bead 1 is provided with an inlet end 4 along the axial direction of the bead 1. The cross-sectional area of ​​the inlet end 4 is smaller than that of the other end. The edge 101 is set relatively inclined to the central axis of the bead 1. When it enters the position of cutting the workpiece, the contact area between the diamond working layer 102 and the workpiece 3 is small. Moreover, the inlet end 4 is set as a frustum or other shape with a buffering effect, which can effectively reduce the impact between the diamond working layer and the workpiece 3, thereby protecting the diamond working layer 102.

[0050] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, 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. Therefore, they should not be construed as limitations on this invention.

[0051] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0052] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0053] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0054] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0055] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A polygonal diamond beaded wire saw, characterized in that, It includes beads (1) and cord (2), the inner diameter of the beads (1) and the outer diameter of the cord (2) are adapted to be connected, the outer wall of the beads (1) is polygonal with multiple edges (101), and the multiple edges (101) are circumferentially spaced along the central axis of the beads (1); The bead (1) includes a cylindrical base (104), the outside of which is provided with a diamond working layer (102) for cutting, and the inside of which is provided with an adhesive filler layer (103) adapted to the string (2), and the edge (101) is provided on the diamond working layer (102). The edge (101) is provided with a rounded corner, and the intersection of the outer periphery of the bead (1) is made by the edge and the arc being tangent, and the radius of the arc R is greater than or equal to 3 * diamond particle size; The solid axial length of the diamond working layer (102) at the edge is greater than the solid axial length at the edge connecting surface (105), and the ratio of their lengths is not less than the ratio of the diameter of the circumcircle of the polygon to the diameter of the incircle of the polygon. The beads (1) have rounded corners at both ends of the axial direction.

2. The polygonal diamond beaded wire saw according to claim 1, characterized in that, The edge (101) is provided with at least four edges.

3. The polygonal diamond bead wire saw according to claim 1, characterized in that, Multiple edges (101) are evenly arranged circumferentially along the central axis of the beads (1).

4. A polygonal diamond beaded wire saw according to any one of claims 1-3, characterized in that, The edge (101) is set parallel to the central axis of the bead (1).

5. A polygonal diamond beaded wire saw according to any one of claims 1-3, characterized in that, One end of the bead (1) along the axial direction of the bead (1) is the inlet end (4), and the cross-sectional area of ​​the inlet end (4) is smaller than the cross-sectional area of ​​the other end.

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