Diamond saw blade based on octopus reinforced flange and preparation method thereof

Abstract

The present invention discloses a diamond saw blade based on an octopus-reinforced flange and a method for manufacturing the same, belonging to the field of diamond tool technology. The diamond saw blade has an octopus-reinforced flange welded to one side of the saw blade base. The raw materials used to manufacture the diamond segment include copper, tin, iron, nickel, a copper-cobalt alloy, diamond, and a rare earth alloy. The present invention achieves rapid cutting speed through optimized segment formulation design. Furthermore, a steel plate with the octopus-reinforced flange is composite-welded to the base surface to improve the saw blade's anti-swing capability and enhance cutting precision. This simultaneously enables the diamond saw blade to achieve optimal cutting performance.

Description

Technical Field

[0001] The present invention relates to the field of diamond tool technology, specifically to a diamond saw blade based on an octopus-shaped reinforced flange and its manufacturing method. This diamond saw blade is primarily used in stone processing facilities for deep processing, vertical cutting, and various angle cutting of various natural and artificial stones, as well as steel and aluminum. Background Art

[0002] Against the backdrop of rapid global economic integration, people are pursuing a more refined lifestyle. This is especially true for the deep processing of stone and profiles, which has evolved from rough processing to today's fine processing, placing higher demands on stone and profile processing tools.

[0003] For many stone and profile processing companies, cutting accuracy is undoubtedly crucial for expanding their market share and customer base. Throughout the entire sawing process, the operating status of the sawing machine and the quality of the saw blade are crucial areas for quality control. However, in actual use, conventional saw blades can cause oscillation due to factors such as foreign matter trapped between the base and the flange, resulting in insufficient cutting accuracy.

[0004] In addition, improving the cutting sharpness of the saw blade and the bonding strength between the diamond and the matrix is also a technical problem that needs to be solved urgently. Summary of the Invention

[0005] The purpose of the present invention is to provide a diamond saw blade based on an octopus reinforced flange and a preparation method thereof, which solves the cutting swing problem existing in conventional saw blades, thereby improving the cutting sharpness of the saw blade and the bonding strength between the diamond and the matrix.

[0006] To achieve the above object, the technical solutions adopted by the present invention are as follows:

[0007] A diamond saw blade based on an octopus-shaped reinforced flange comprises a circular saw blade base and a plurality of diamond segments evenly arranged on the edge of the base, wherein the octopus-shaped flange is welded on one side surface of the saw blade base.

[0008] The saw blade base is made of 65Mn or 45Mn2V.

[0009] The octopus flange has a center hole, which has the same size and position as the center hole of the saw blade base; the edge of the octopus flange has eight evenly distributed protrusions, and the outer end surfaces of the protrusions have a smooth transition.

[0010] The thickness of the octopus flange is 1-2 times the thickness of the saw blade base; three small holes are arranged radially along the octopus flange on the protrusion, and the diameters of the three small holes gradually increase from the outside to the inside.

[0011] The raw materials for preparing the diamond tool head are composed of copper, iron, nickel, copper-cobalt alloy, tin, rare earth alloy and diamond, wherein the diamond particle size is 70 / 80, 80 / 100 or 100 / 120, and the compressive strength is 15-25kg; the rare earth alloy is cerium-aluminum alloy, and the cerium content in the cerium-aluminum alloy is 5-20wt.%; the chemical composition of the copper-cobalt alloy is: cobalt (Co) 15-40wt.%, copper (Cu) 8-25wt.%, iron (Fe) 20-45wt.%, and silicon (Si) 3-25wt.%.

[0012] Preferably, the diamond segment raw material comprises the following components in parts by weight:

[0013] 31-43 parts of copper, 21-30 parts of iron, 3-15 parts of nickel, 11-23 parts of copper-cobalt alloy, 2-11 parts of tin, 0.3-1.1 parts of rare earth alloy, and 1.1-2.4 parts of diamond.

[0014] Preferably, the diamond segment raw material comprises the following components in parts by weight:

[0015] 35-42 parts of copper, 24-29 parts of iron, 4-13 parts of nickel, 14-21 parts of copper-cobalt alloy, 5-19 parts of tin, 0.3-0.8 parts of rare earth alloy, and 1.5-2.1 parts of diamond.

[0016] More preferably, the diamond segment raw material comprises the following components in parts by weight:

[0017] 35 parts of copper, 28 parts of iron, 10 parts of nickel, 18 parts of copper-cobalt alloy, 5 parts of tin, 0.6 parts of rare earth alloy, and 1.8 parts of diamond.

[0018] The method for preparing the diamond saw blade based on the octopus reinforced flange comprises the following steps:

[0019] (1) Matrix processing:

[0020] According to the drawing requirements, lathe, laser cut, heat treat, and level the required saw blade base and octopus flange;

[0021] (2) Diamond Segment Sintering:

[0022] The raw materials of the diamond segment are mixed and cold pressed into shape, and then hot pressed and sintered. The temperature during hot pressing and sintering is 600-800℃ and the pressure is 200-300kg / cm 2, keep warm for 1-5 minutes. After the cutter head cools down, remove it and remove the burrs, grind the arc, and check the screening size for use;

[0023] (3) High-frequency welding is used to connect the saw blade base and the diamond cutter head into one body; the connection temperature is 700-880°C, and silver solder is used during the connection process. The silver solder melts and welds the cutter head and the base together;

[0024] (4) The octopus flange is welded to the surface of the saw blade using a spot welder, and the surface of the diamond saw blade after the treatment is spray-painted and dried to obtain the diamond saw blade based on the octopus reinforced flange.

[0025] The design principles and beneficial effects of the present invention are as follows:

[0026] 1. By spot welding an octopus flange (made of the same material as the base) on the surface of the diamond saw blade base, the saw blade's anti-swinging ability can be improved, and the cutting precision can be enhanced. At the same time, the cutting weight is reduced by 1 / 3 compared to the flange weight of an ordinary disc, which reduces the equipment bearing wear and cutting energy consumption to a certain extent, while allowing the diamond saw blade to achieve optimal cutting ability.

[0027] 2. The present invention optimizes the design of the cutter head formula, thereby improving the affinity between the diamond and the metal matrix, that is, the metal matrix's grip on the diamond and its sharpness, and also improving the cutter head's hardness, wear resistance, and bending strength, as follows:

[0028] In the present invention, Cu plays a major role in the matrix and acts as a bond, but Cu has poor wettability on diamond. By adding an appropriate amount of Ni to the cutter head formula, Ni and Cu can be infinitely miscible. At the same time, liquid Ni can firmly adhere to the diamond surface to form an extremely thin film, thereby enhancing the adhesion of Ni, Cu and diamond.

[0029] Fe is a strong carbide-forming element. It can react with the carbon element on the surface of diamond to form iron-carbon compound Fe3C to improve the bonding strength between the matrix and diamond. Fe can also react with Sn to form Fe3Sn. The formation of Fe3Sn phase can also strengthen the bonding strength between various metal elements in the matrix.

[0030] Aluminum is introduced into the tool head formula in the form of cerium-aluminum alloy powder. Al has varying degrees of compatibility with copper, iron, nickel, and tin, forming various intermetallic compounds to strengthen the matrix. Al also has good wettability with diamond, and its low melting point and low price minimize diamond damage and reduce costs.

[0031] The Co in the blade formula is quoted in the form of copper-cobalt alloy. Co can form carbide with diamond and at the same time adhere to the diamond surface with an extremely thin Co film, greatly improving the bonding strength between the matrix and the diamond.

[0032] 3. The present invention incorporates an appropriate amount of rare earth alloy powder into the formula, capturing a large amount of non-metallic impurities such as O, S, N, H, and C in the matrix, forming non-metallic compounds that are dispersed throughout the matrix. The rare earth elements also react with Cu and Ni metals to form intermetallic compounds, which tend to make the matrix brittle and easily release chips during abrasion, reducing the wear resistance of the matrix. However, this has little effect on the wear resistance of the saw blade, thereby ensuring that the diamond blade has a good cutting edge height, facilitating rapid cutting and significantly improving the sharpness of the saw blade.

[0033] 4. Surface oxidation is common during conventional mechanical mixing (or mechanical ball milling) and sintering of aluminum and rare earth powders, resulting in poor sintering activity. This results in an uneven matrix material composition, poor wear resistance, and insufficient diamond particle retention. In the present invention, rare earth elements are introduced into the tool head in the form of cerium-aluminum alloy powder, which is less susceptible to oxidation during mixing and sintering. This results in a uniform matrix material composition and improved bonding between the diamond and the matrix.

[0034] 5. Currently, some countries strictly restrict the export of cobalt ore, limiting the export of primary cobalt products, which affects the domestic supply of cobalt raw materials. The present invention uses copper-cobalt alloy, a primary cobalt product, as the raw material, significantly reducing production costs. Furthermore, based on the selection of copper-cobalt alloy as the raw material, the other raw materials are optimized in proportion to achieve excellent performance of the tool head. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 Diagram of the diamond saw blade for the Octopus reinforced flange; (a) and (c) are two surface views; (b) is a side view.

[0036] Figure 2 Stereoscopic image of the diamond saw blade reinforced for the octopus flange. DETAILED DESCRIPTION

[0037] In order to further understand the present invention, the present invention is described below with reference to examples. However, the examples are only for further elaboration of the features and advantages of the present invention, rather than for limitation of the claims of the present invention.

[0038] like Figure 1-2As shown, the diamond saw blade of the present invention comprises a circular saw blade base and multiple diamond segments evenly spaced along its edge. The saw blade base can be made of 65Mn or 45Mn2V. An octopus-shaped flange is welded to one side of the saw blade base. The flange has a center hole that is the same size and position as the center hole (mounting hole) of the saw blade base. The flange also features eight evenly spaced protrusions along its edge, each with a smoothly rounded outer end surface.

[0039] The thickness of the octopus flange is 1-2 times the thickness of the saw blade base; three small holes are arranged radially along the octopus flange on the protrusion, and the diameters of the three small holes gradually increase from the outside to the inside.

[0040] The raw materials for preparing the diamond segments in the following embodiments are composed of copper, iron, nickel, copper-cobalt alloy, tin, rare earth alloy and diamond, wherein the diamond particle size is 70 / 80, 80 / 100 or 100 / 120 and the compressive strength is 15-25 kg; the rare earth alloy is a cerium-aluminum alloy, and the cerium content in the cerium-aluminum alloy is 10 wt.%; the main chemical components of the copper-cobalt alloy are: 30 wt.% cobalt (Co), 15 wt.% copper (Cu), 35 wt.% iron (Fe), and 15 wt.% silicon (Si).

[0041] Example 1:

[0042] The process of preparing the diamond saw blade based on the octopus reinforced flange in this embodiment is as follows:

[0043] Take 3.8kg of copper powder, 2.4kg of iron, 1.2kg of nickel, 2.0kg of copper-cobalt alloy, and 0.8kg of tin and put them into a mixing barrel and mix for 30 minutes. Then add 0.08kg of rare earth alloy and 0.20kg of diamond. After continuing to mix for 2 hours, pour the powder into the mold and cold press it into shape. Then, hot press sintering is carried out. The hot press sintering temperature is 805℃ and the pressure is 260kg / cm 2 , heat preservation time 4 minutes.

[0044] Place the cutter head and silver solder sheet on the corresponding base, adjust the welding position, heat and melt the silver solder sheet, and weld the cutter head and base together using a high-frequency welding machine at a welding temperature of 810°C. Grind the cutter head with a grinding wheel and belt to expose the diamond.

[0045] The octopus flange is welded to the surface of the saw blade with a spot welder. The surface of the diamond saw blade is sprayed with paint and dried to prevent rust. Finally, the blade is welded at 600N / mm 2 Strength standard: Each diamond cutter head is tested for welding strength and qualified.

[0046] The hardness of the diamond saw blade in this embodiment is 105HRB, and the relative bending strength of the blade (the ratio of the bending strength of the matrix material after the diamond is added to the bending strength of the matrix material) is 95.6%, indicating that the diamond has a good grip on the matrix material. The test data of the saw blade cutting granite is shown in Table 1.

[0047] Example 2:

[0048] The process of preparing the diamond saw blade based on the octopus reinforced flange in this embodiment is as follows:

[0049] 3.6 kg of copper powder, 2.9 kg of iron, 1.2 kg of nickel, 1.7 kg of copper-cobalt alloy, and 0.6 kg of tin were placed in a mixing barrel and mixed for 30 minutes. 0.4 kg of rare earth alloy and 0.20 kg of diamond were added. After mixing for 2 hours, the powder was poured into a mold and cold-pressed. Then, hot-pressed sintering was performed at a temperature of 810 ° C and a pressure of 260 kg / cm 2 , heat preservation time 4 minutes.

[0050] Place the cutter head and silver solder sheet on the corresponding substrate position, adjust the welding position, heat and melt the silver solder sheet to weld the cutter head and substrate together, the welding temperature is 810℃. Grind the cutter head with a grinding wheel and belt to expose the diamond.

[0051] The octopus flange is welded to the surface of the saw blade with a spot welder. The surface of the diamond saw blade is sprayed with paint and dried to prevent rust. Finally, the blade is welded at 600N / mm 2 Strength standard: Each diamond cutter head is tested for welding strength and qualified.

[0052] The hardness of the diamond saw blade in this embodiment is 108HRB, and the relative bending strength of the blade (the ratio of the bending strength of the matrix material after the diamond is added to the bending strength of the matrix material) is 95.2%, indicating that the diamond has a good grip on the matrix material. The test data of the saw blade cutting granite is shown in Table 1.

[0053] Example 3:

[0054] The process of preparing the diamond saw blade based on the octopus reinforced flange in this embodiment is as follows:

[0055] Take 3.5kg of copper powder, 2.8kg of iron, 1.0kg of nickel, 1.8kg of copper-cobalt alloy, and 0.5kg of tin and put them into a mixing barrel and mix for 30 minutes. Then add 0.06kg of rare earth alloy and 0.18kg of diamond. After continuing to mix for 3 hours, pour the powder into the mold and cold press it into shape. Then, hot press sintering is carried out. The hot press sintering temperature is 800℃ and the pressure is 250kg / cm 2 , heat preservation time 4 minutes.

[0056] Place the cutter head and silver solder sheet on the corresponding base, adjust the welding position, heat and melt the silver solder sheet, and weld the cutter head and base together using a high-frequency welding machine at a welding temperature of 810°C. Grind the cutter head with a grinding wheel and belt to expose the diamond.

[0057] The octopus flange is welded to the surface of the saw blade with a spot welder. The surface of the diamond saw blade is sprayed with paint and dried to prevent rust. Finally, the blade is welded at 600N / mm 2 Strength standard: Each diamond cutter head is tested for welding strength and qualified.

[0058] The diamond saw blade of this embodiment has a hardness of 102 HRB and a relative bending strength of 96.2% (the ratio of the bending strength of the matrix material after the diamond is added to the bending strength of the matrix material), indicating that the diamond has a good grip on the matrix material. Table 1 shows the test data of the saw blade cutting granite.

[0059] Table 1 Experimental data of saw blade cutting granite in Examples 1-3

[0060]

[0061] As can be seen from Table 1, the sharpness and life (wear resistance) of the diamond saw blade of the present invention are both excellent, indicating that the wear resistance of the matrix is weaker than that of the saw blade, and the blade height is large, but the matrix has a strong grip on the diamond, the saw blade has better wear resistance, and therefore the saw blade has a good life.

Claims

1. A diamond saw blade based on an octopus reinforced flange, characterized by: The diamond saw blade comprises a circular saw blade base and a plurality of diamond segments evenly arranged on the edge of the base, wherein an octopus flange is welded on one side surface of the saw blade base; the raw materials for preparing the diamond segments are composed of copper, iron, nickel, copper-cobalt alloy, tin, rare earth alloy and diamond. The raw materials for the diamond segments are composed of the following by weight: 31-43 parts of copper, 21-30 parts of iron, 3-15 parts of nickel, 11-23 parts of copper-cobalt alloy, 2-11 parts of tin, 0.3-1.1 parts of rare earth alloy, 1.1-2.4 parts of diamond; The rare earth alloy is a cerium-aluminum alloy, and the cerium content in the cerium-aluminum alloy is 5-20wt.%; the chemical composition of the copper-cobalt alloy is: 15-40wt.% cobalt, 8-25wt.% copper, 20-45wt.% iron, and 3-25wt.% silicon.

2. The diamond saw blade based on the octopus reinforced flange according to claim 1, characterized in that: The saw blade base is made of 65Mn or 45Mn2V.

3. The diamond saw blade based on the octopus reinforced flange according to claim 1 or 2, characterized in that: The octopus flange has a center hole, which is the same size and position as the center hole of the saw blade base; the edge of the octopus flange has eight evenly distributed protrusions, and the outer end surfaces of the protrusions are smoothly transitioned.

4. The diamond saw blade based on the octopus reinforced flange according to claim 3, characterized in that: The thickness of the octopus flange is 1-2 times the thickness of the saw blade base; three small holes are arranged radially along the octopus flange on the protrusion, and the diameters of the three small holes gradually increase from the outside to the inside.

5. The diamond saw blade based on the octopus reinforced flange according to claim 1, characterized in that: The diamond segment raw material has a diamond particle size of 70 / 80, 80 / 100 or 100 / 120 and a compressive strength of 15-25 kg.

6. The diamond saw blade based on the octopus reinforced flange according to claim 1, characterized in that: The diamond segment raw material composition is as follows by weight: 35 parts of copper, 28 parts of iron, 10 parts of nickel, 18 parts of copper-cobalt alloy, 5 parts of tin, 0.6 parts of rare earth alloy, and 1.8 parts of diamond.

7. The method for preparing a diamond saw blade based on an octopus-shaped reinforced flange according to claim 1, characterized in that: The method comprises the following steps: (1) Matrix processing: According to the drawing requirements, lathe, laser cut, heat treat, and level the required saw blade base and octopus flange; (2) Diamond segment sintering: Mix all the raw materials of the diamond cutter head and then cold press to form it, then hot press and sinter it. After the cutter head cools down, take it out and remove the burrs, grind the curvature, and check the size of the cutter head before use. (3) High-frequency welding is used to connect the saw blade base and the diamond cutter head into one; the connection temperature is 700-880℃, and silver solder is used during the connection process. The silver solder melts and welds the cutter head and base together; (4) The octopus flange is welded to the surface of the saw blade using a spot welding machine, and the surface of the diamond saw blade after the treatment is spray-painted and dried to obtain the diamond saw blade based on the octopus reinforced flange.

8. The method for preparing a diamond saw blade based on an octopus-shaped reinforced flange according to claim 7, characterized in that: In step (2), the temperature during hot pressing and sintering is 600-800°C and the pressure is 200-300 kg / cm 2 , insulation time 1-5 minutes.

Images