Method for manufacturing an ultra-fine wire saw

Abstract

The application discloses a preparation method of an ultra-fine rope saw, which comprises the following steps: S1, using tungsten wire or 310S steel wire as the high-temperature-resistant wire rope; S2, weaving the high-temperature-resistant wire rope in butt joint to form a closed ring or cutting to a predetermined length; S3, manufacturing diamond brazing material sheets and dividing the diamond brazing material sheets into a plurality of diamond brazing material blocks; S4, bonding the plurality of diamond brazing material blocks on the high-temperature-resistant wire rope and then drying; and S5, brazing the dried high-temperature-resistant wire rope and the diamond brazing material blocks to tightly combine the two and form the ultra-fine rope saw. The ultra-fine rope saw prepared by the method is characterized in that the diamond brazing material blocks are directly brazed on the surface of the high-temperature-resistant wire rope, the base body is removed, the thickness of the base body and the gap between the base body and the steel wire rope are reduced, the diameter of the rope saw is smaller and reaches 1-4 mm, the rope saw is especially suitable for cutting of precious materials, the structure is more compact, the rope saw is thinner, the cutting gap is smaller, the material yield is higher, the loss is lower, and the environment is protected and saved.

Description

Technical Field

[0001] This invention relates to the field of diamond wire saw technology, and in particular to a method for preparing an ultra-fine wire saw. Background Technology

[0002] Diamond wire saws, as a new type of diamond cutting tool, are mainly used in non-metallic hard and brittle materials such as stone and concrete, especially in the field of stone cutting.

[0003] Existing diamond wire saws consist of a steel wire rope and diamond beads. The diamond beads comprise a matrix and a core, both cylindrical in shape. The core is fixed to the outer wall of the matrix and contains diamond particles. The matrix is ​​coaxially fitted onto the steel wire rope, with its inner diameter larger than the outer diameter of the steel wire rope, allowing a plastic injection layer to fill the gap between the matrix and the steel wire rope. The manufacturing process of the diamond wire saw involves threading multiple cylindrical diamond beads onto the steel wire rope, and then filling the space between the diamond beads and the steel wire rope using injection molding or hot pressing processes to provide fixation and separation.

[0004] Currently, diamond wire saws manufactured using traditional diamond production processes have relatively large diameters. This is because the diamond beads consist of a matrix and a core, both of which have a certain thickness. There is also a gap between the matrix and the wire rope to fill with rubber and plastic material. Most existing diamond wire saws have an outer diameter between 6 and 11 mm, with a cutting kerf of approximately 10 mm. During the cutting process, the wide kerf results in low yield, high raw material loss, and resource waste. Summary of the Invention

[0005] To address the aforementioned problems, the purpose of this invention is to provide a method for preparing an ultra-fine wire saw, thereby solving the problem of resource waste caused by the large diameter of wire saws produced by existing diamond wire saw manufacturing processes, which results in large cutting gaps, low yield, and high raw material loss.

[0006] This invention is implemented as follows:

[0007] A method for preparing an ultrafine wire saw includes the following steps:

[0008] S1. Select high-temperature resistant wire rope and clean it. The high-temperature resistant wire rope is made of tungsten wire or 310S steel wire.

[0009] S2. The first and last ends of the cleaned high-temperature resistant wire rope are braided together to form a closed loop without joints, or the cleaned high-temperature resistant wire rope is cut to a predetermined length.

[0010] S3. Fabricate diamond brazing filler sheets and divide the diamond brazing filler sheets into multiple diamond brazing filler blocks;

[0011] S4. After bonding multiple diamond brazing blocks onto the high-temperature resistant wire rope in an orderly or disordered manner, dry them.

[0012] S5. Brazing the dried high-temperature resistant wire rope and diamond brazing block together to form an ultra-fine wire saw.

[0013] Furthermore, the steps in step S3 for fabricating the diamond brazing filler sheet are as follows:

[0014] S31. After the brazing filler metal is mixed evenly, it is placed between the first plate and the second plate and pressed together until solidification to form a brazing filler metal sheet.

[0015] S32. Press the solder sheet to the predetermined thickness;

[0016] S33. Take diamond particles and evenly sprinkle them on the surface of the brazing filler sheet with a certain thickness obtained in step S32, and apply pressure to make the diamond particles and the brazing filler sheet fully bond together to form a diamond brazing filler sheet.

[0017] Furthermore, in step S31, the brazing material and adhesive are placed in a vacuum mixer and stirred evenly for at least five minutes, and the total amount of brazing material and adhesive does not exceed 0.5 kg.

[0018] Furthermore, in step S32, a rolling mill is used to roll the brazing filler sheet multiple times to a predetermined thickness, the thickness of which is 1.1 to 1.6 times the diameter of the diamond particles.

[0019] Furthermore, in step S4, diamond brazing blocks are bonded to the high-temperature resistant wire rope using glue, with multiple diamond brazing blocks arranged along the length of the high-temperature resistant wire rope.

[0020] Furthermore, in step S4, natural drying is used, and the drying time is eight hours.

[0021] Furthermore, the high-temperature resistant wire rope with diamond brazing filler attached in step S4 is placed in an oven for drying for two hours at a temperature of 70°C.

[0022] Furthermore, the brazing in step S5 is performed using vacuum furnace brazing or continuous brazing, and the brazing temperature is 900-1000℃.

[0023] Furthermore, the high-temperature resistant wire rope is a single-strand rope or a multi-strand rope, and the outer diameter of the high-temperature resistant wire rope is 0.1 to 2.5 mm.

[0024] Furthermore, the outer diameter of the ultrafine wire saw in step S5 is 1–4 mm.

[0025] The beneficial effects of this invention are:

[0026] The method for preparing the ultra-fine wire saw of this invention uses tungsten wire or 310S steel wire instead of ordinary steel wire rope in the high-temperature alloy rope. This ensures that the rope does not deform during high-temperature heating in the brazing furnace and that its tensile strength is not affected, thus guaranteeing that the strength of the diamond wire saw rope meets the usage requirements. Diamond particles and brazing filler metal are directly brazed onto the surface of the tungsten wire or 310S steel wire, removing the substrate and reducing the thickness of the substrate and the gap between the substrate and the steel wire rope. This results in a smaller diameter diamond wire saw, ranging from 1 to 4 mm. The ultra-fine wire saw prepared by this invention can not only cut ordinary stone, but is also particularly suitable for cutting precious materials due to its smaller diameter. It features a more compact structure, a finer wire saw, a smaller cutting kerf, higher yield, lower waste, and is environmentally friendly and economical. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the production process of the present invention;

[0028] Figure 2 A three-dimensional structural schematic diagram of the ultrafine wire saw with multi-stranded rope prepared according to the present invention;

[0029] Figure 3 This is a three-dimensional structural diagram of the ultrafine wire saw with a single strand of wire prepared according to the present invention.

[0030] Explanation of reference numerals in the attached figures:

[0031] 1. High-temperature resistant wire rope; 2. Diamond brazing filler block. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0033] Example 1:

[0034] The preparation method of the ultrafine wire saw of the present invention includes the following steps, and please refer to [link / reference]. Figure 1 The flowchart shown:

[0035] S1. Select a high-temperature resistant wire rope 1 and electrolytically clean it. The high-temperature resistant wire rope 1 is made of tungsten wire or 310S steel wire. It should be noted that other metal materials that can withstand high temperatures are also applicable and are not limited here. Preferably, a metal material that can withstand temperatures up to about 1000℃ is selected. Because the metallographic structure of ordinary steel wire rope changes when the heating temperature exceeds 200 degrees, the tensile strength also decreases and cannot meet the strength requirements. The high-temperature resistant wire rope 1 of this invention uses tungsten wire or 310S steel wire instead of ordinary steel wire rope. Under high-temperature heating, they will not deform and their strength will not be lost. This can effectively prevent the high-temperature resistant wire rope 1 from being deformed by heat and losing strength when it enters the brazing furnace for brazing.

[0036] S2. The first and last ends of the cleaned high-temperature resistant wire rope 1 are braided together to form a seamless closed loop, or the cleaned high-temperature resistant wire rope 1 is cut to a predetermined length. In this embodiment, the high-temperature resistant wire rope 1 can be braided into a seamless loop or cut into single wires of a certain length, depending on actual needs. The braiding method of the high-temperature resistant wire rope 1 is not limited here, as long as it can be braided into a seamless closed loop, ensuring that the joint is flat and durable, and preventing the wire saw from being affected by uneven joints during the cutting process, thus shortening the wire saw's service life.

[0037] S3. Fabricate a diamond brazing sheet and divide it into multiple diamond brazing blocks 2 of the same shape and size. Generally, the diamond brazing blocks 2 are rectangular blocks, but they can also be cut into other shapes according to production needs, which is not limited here.

[0038] The specific steps for manufacturing diamond brazing filler sheets are as follows:

[0039] S31. Place the brazing filler metal and adhesive into a vacuum mixer and mix thoroughly for at least five minutes. The total amount of brazing filler metal and adhesive added to the vacuum mixer at one time should not exceed 0.5 kg. The brazing filler metal can be metal powder or alloy powder, including one or more of the following elements: B, Si, P, Co, Cr, Ni, W, WC, Mn, Fe, Cu, Sn, Mo, etc. The particle size of the brazing filler metal powder is between 200 and 400 mesh. After thorough mixing in the vacuum mixer, the brazing filler metal is bonded together with adhesive to form a paste. Take the mixed paste and spread it evenly between the first and second plates. Close the first and second plates together and apply a certain pressure to press the brazing filler metal in the middle. Press for a period of time until the brazing filler metal solidifies and forms a brazing sheet. Then remove the brazing sheet from the first and second plates. In this embodiment, the first plate and the second plate are preferably made of anti-stick silicone plates to prevent the solder sheet from being partially missing or incomplete due to local adhesion when it is peeled off from the first plate and the second plate.

[0040] S32. Press the brazing filler metal sheet to a predetermined thickness. Specifically, a pair of rotating rollers in a rolling mill can be used to press the filler metal sheet to the predetermined thickness. Preferably, the center position of one of the rollers can be adjusted to adjust the center distance between the two rollers, thus accommodating the rolling of filler metal sheets of various thicknesses. After the filler metal sheet is placed between the pair of rollers and pressed, a uniform filler metal sheet with a certain thickness is formed. Rolling, pressing, or other methods can also be used to press the filler metal sheet to the predetermined thickness. Preferably, the thickness of the filler metal sheet is about 1.1 to 1.6 times the diameter of the diamond to ensure the exposed height of the diamond particles and thus improve the cutting effect.

[0041] S33. Diamond particles are evenly sprinkled onto the surface of the brazing filler sheet of a certain thickness obtained in step S32, and pressure is applied to ensure the diamond particles and brazing filler sheet are fully bonded together to form a diamond brazing filler sheet. The diamond particles comprise 5%–15%, the brazing filler comprises 70%–90%, and the adhesive comprises 5%–15%. The diamond particles are 40–60 mesh saw-grade diamonds. Specifically, diamond particles are evenly sprinkled onto the surface of the first or second plate. Then, the brazing filler sheet of a certain thickness obtained in step S32 is placed on top of the diamond particles. The first and second plates are then closed, and a certain pressure is applied for pretreatment. A pressure of 0.1 MPa is used for pretreatment to firmly bond the diamond particles and brazing filler sheet together to form a diamond brazing filler sheet, preventing loosening or movement under subsequent high-temperature conditions. The diamond brazing filler sheet is then removed from between the first and second plates and cut into multiple diamond brazing filler blocks 2 of the same shape and size. Generally, the diamond brazing filler block 2 is rectangular, but it can also be cut into other shapes according to production needs, which is not limited here.

[0042] S4. After bonding the multiple diamond brazing blocks 2 from step S3 to the high-temperature resistant wire rope 1 in an orderly or random manner, dry them. Use glue to bond the diamond brazing blocks 2 to the high-temperature resistant wire rope 1, arranging them along the length of the wire rope 1. Note that the side of the diamond brazing block 2 with diamond particles evenly attached is the working surface for cutting; the side opposite the working surface is wrapped with glue and bonded to the outside of the high-temperature resistant wire rope 1. The multiple diamond brazing blocks 2 are evenly or randomly arranged along the length of the high-temperature resistant wire rope 1, depending on production needs. After bonding the diamond brazing blocks to the outside of the high-temperature resistant wire rope 1, dry it. Drying can be done naturally or in an oven; to improve productivity, oven drying is preferred. When the high-temperature resistant wire rope 1 with diamond brazing filler block 2 bonded to it in step S4 is placed in an oven for drying, the drying temperature is controlled at around 70°C and the drying time is two hours to ensure the bonding strength between the two. When natural drying is used, the drying time is eight hours.

[0043] S5. Brazing the dried high-temperature resistant wire rope 1 and diamond brazing block 2 tightly bonds them together to form an ultra-fine wire saw. Brazing is performed in a vacuum furnace or continuously at a temperature of 900–1000℃. The high-temperature resistant wire rope 1 with the diamond brazing block 2 bonded to it is placed in a vacuum furnace for high-temperature brazing under a vacuum environment with a vacuum degree of 0.01 Pa. During the brazing process, the diamond brazing block 2 and the high-temperature resistant wire rope 1 are heated simultaneously. When the diamond brazing block 2 approaches or reaches its melting point, due to the majority of its components being brazing material, it collapses, further exposing the diamond particles attached to it. Simultaneously, the brazing material reacts chemically with the high-temperature resistant wire rope 1, causing the diamond brazing block 2 to form a metal-like solidified substance that adheres to the outer surface of the high-temperature resistant wire rope 1. This allows the diamond particles to be exposed evenly, with the height of the diamond particles exposed above the brazing filler being 50% to 70% of the diamond particle diameter, thus achieving a high utilization rate. At the same time, the thinner brazing filler prevents the diamond particles from being buried in the brazing filler, thus preventing the waste of diamond material. This further saves diamond particles while increasing the exposure of the diamond particles and improving the efficiency of use.

[0044] In this embodiment, the high-temperature resistant wire rope 1 is made of tungsten wire or 310S steel wire. When the tungsten wire or 310S steel wire is brazed in the brazing furnace, it effectively ensures that the high-temperature resistant wire rope 1 does not deform or lose strength during high-temperature heating, thus meeting the cutting strength requirements of the wire saw. The high-temperature resistant wire rope 1 is a single-strand or multi-strand rope, and its outer diameter is 0.1–2.5 mm. Figure 2The high-temperature resistant wire rope 1 shown is a multi-strand rope, which is formed by intertwining and crisscrossing multiple tungsten wires or 310S steel wires. The specific number of tungsten wires or 310S steel wires is not limited here; it can be three, five, or seven, etc., depending on the production requirements and strength needed. The outer diameter of the multi-strand rope after twisting is 0.1–2.5 mm. Figure 3 The high-temperature resistant wire rope 1 shown can also be a single-strand rope, with an outer diameter of 0.1 to 2 mm.

[0045] It is particularly important to note that the outer diameter of the formed ultrafine wire saw in step S5 is 1–4 mm, while the outer diameter of ordinary diamond wire saws is mostly between 6–11 mm. Therefore, in this embodiment, the ultrafine wire saw has a smaller outer diameter and a smaller cutting kerf, resulting in a smaller cutting kerf during the cutting process, higher material yield, less raw material loss, resource conservation, and environmental benefits. The ultrafine wire saw prepared by this invention can not only cut ordinary stone, but is also particularly suitable for cutting precious materials due to its smaller diameter.

[0046] In the preparation method of the ultrafine wire saw of the present invention, tungsten wire or 310S steel wire is used as high-temperature resistant wire rope 1 instead of ordinary steel wire that is not resistant to high temperature. Diamond brazing material sheets are directly arranged on the surface of tungsten wire or 310S steel wire, and then brazing is performed in a brazing furnace so that multiple diamond brazing material sheets are fixedly brazed on the surface of the high-temperature resistant wire rope 1. The multiple diamond brazing material sheets are arranged in an orderly or disordered manner on the high-temperature resistant wire rope 1 to form an ultrafine wire saw.

[0047] The high-temperature resistant wire rope 1 of this invention uses tungsten wire or 310S steel wire instead of ordinary steel wire rope. This high-temperature resistant wire rope 1 can withstand high-temperature heating without deformation or affecting tensile strength during brazing in a brazing furnace, ensuring that the strength of the diamond wire saw rope meets usage requirements. Diamond brazing filler sheets, composed of diamond particles and metal brazing filler, are directly bonded and brazed onto the surface of the tungsten wire or 310S steel wire, removing the substrate and reducing its thickness and the gap between the substrate and the steel wire rope. This results in a smaller diameter diamond wire saw, ranging from 1 to 4 mm. The ultra-fine wire saw prepared by this invention can not only cut ordinary stone, but is also particularly suitable for cutting precious materials due to its smaller diameter. It has a more compact structure, a finer wire saw, a smaller cutting kerf, higher yield, lower waste, and is environmentally friendly and economical.

[0048] Example 2:

[0049] Production method of ordinary diamond wire saw:

[0050] Diamond particles and metal brazing filler are mixed with organic adhesive to form a paste. A steel pipe with an outer diameter of 4–7 mm and an inner diameter of 3–6 mm is coated evenly with the paste on its outer wall and then brazed in a vacuum brazing furnace. After exiting the furnace, the steel pipe is cut into sections of 8–15 mm in length to obtain diamond beads containing a metal matrix, with a diameter of 6–10 mm. A steel wire rope with a diameter of 2–5 mm is taken, and the diamond beads are looped onto the wire rope. The ends of the wire rope are then braided into a ring. Adhesive is applied at equal intervals along the wire rope according to the pitch length. The diamond beads are then placed one by one on the adhesive areas. TPU is heated until melted and injected into the gap between the inner wall of the diamond beads and the steel wire rope. After the TPU cools and solidifies, the diamond beads and the steel wire rope are bonded and fixed, resulting in a diamond wire saw with a diameter of 6–10 mm.

[0051] The diamond wire saws formed in the two embodiments above were subjected to performance tests, and the test data were compiled as shown in Table 1.

[0052] Table 1 Comparison of parameters between conventional and ultrafine wire saws

[0053]

[0054]

[0055] As shown in Table 1, Example 1 is an ultra-fine wire saw manufactured using the production method of this invention, and Example 2 is a conventional wire saw manufactured using traditional production methods. The ultra-fine wire saw in Example 1 has a diameter of 1-4 mm, smaller than the 6-10 mm diameter of the conventional wire saw. This results in a smaller cutting kerf, higher yield, less raw material loss, resource conservation, and environmental friendliness. Due to its smaller diameter, the ultra-fine wire saw is particularly suitable for cutting precious materials. Tensile strength tests were conducted on the wire saws in Examples 1 and 2 sequentially. Table 1 shows that although the ultra-fine wire saw has a smaller diameter, its tensile strength is 1960 MPa, while the conventional diamond wire saw, with a larger diameter, has a tensile strength of only 1770 MPa. Therefore, the smaller-diameter ultra-fine wire saw has a higher tensile strength than the larger-diameter conventional wire saw and also improves its service life. Furthermore, the exposed diamond height in an ultrafine wire saw is 50%–70% of the diamond diameter, while in a conventional wire saw it is 30%–40%. The higher exposed diamond height in an ultrafine wire saw makes it sharper, resulting in better cutting performance and significantly reduced cutting force and heat. The higher diamond exposure height also provides ample chip space, effectively preventing chip clogging.

[0056] The bonding force between the diamond brazing block 2 and the high-temperature resistant wire rope 1 in the ultra-fine wire saw of Example 1 was tested. When the pressure reached 850 MPa, the diamond brazing block 2 and the high-temperature resistant wire rope 1 loosened and gradually detached. The bonding force between the diamond beads and the steel wire rope in the ordinary wire saw of Example 2 was tested. When the pressure reached 700 MPa, the diamond beads separated from the steel wire rope and detached. As can be seen from Table 1, the ultra-fine wire saw produced by the method of the present invention, with the diamond brazing block with attached diamonds as the working layer, has a greater bonding force with the high-temperature resistant wire rope 1 and a longer cutting life. It effectively solves the problem of easy detachment of diamond beads in existing ordinary diamond wire saws and provides a new direction for the preparation process of ultra-fine diamond wire saws.

[0057] In summary, the high-temperature resistant wire rope 1 of this invention uses tungsten wire or 310S steel wire instead of ordinary steel wire rope. The high-temperature resistant wire rope 1 can withstand high-temperature heating without deformation or affecting tensile strength during brazing in the brazing furnace, ensuring that the strength of the diamond wire saw rope meets usage requirements. Diamond brazing material sheets, composed of diamond particles and metal brazing material, are directly bonded and brazed onto the surface of the tungsten wire or 310S steel wire, removing the substrate and reducing the thickness of the substrate and the gap between the substrate and the steel wire rope, resulting in a smaller diameter diamond wire saw of 1-4 mm. Furthermore, the direct and firm brazing of diamond particles onto the high-temperature resistant wire rope 1 with brazing material improves the bonding force between the two and the overall tensile strength of the formed wire saw. The higher diamond exposure height and sufficient chip space effectively prevent chip clogging, improving cutting efficiency and the service life of the wire saw.

[0058] While the present invention discloses preferred embodiments to achieve the above objectives, these are not intended to limit the structural features of the invention. Anyone skilled in the art should know that any easily conceived variations or modifications are possible within the technical spirit of the invention and are covered by the claims of the present invention.

Claims

1. A method for preparing an ultrafine wire saw, characterized in that, The steps include the following: S1. Select a high-temperature resistant wire rope (1) and clean it. The high-temperature resistant wire rope (1) is made of tungsten wire or 310S steel wire. S2. The first and last ends of the cleaned high-temperature resistant wire rope (1) are braided together to form a closed loop without joints, or the cleaned high-temperature resistant wire rope (1) is cut to a predetermined length. S3. Fabricate diamond brazing sheet and divide the diamond brazing sheet into multiple diamond brazing blocks (2). S4. After bonding multiple diamond brazing blocks (2) onto the high-temperature resistant wire rope (1) in an orderly or disordered manner, dry them. S5. Brazing the dried high-temperature resistant wire rope (1) and diamond brazing block (2) together to form an ultra-fine wire saw. The steps for fabricating the diamond brazing filler sheet in step S3 are as follows: S31. After the brazing filler metal is mixed evenly, it is placed between the first plate and the second plate and pressed together until solidification to form a brazing filler metal sheet. S32. Press the solder sheet to the predetermined thickness; S33. Take diamond particles and evenly sprinkle them on the surface of the brazing filler sheet with a certain thickness obtained in step S32, and apply pressure to make the diamond particles and the brazing filler sheet fully bond together to form a diamond brazing filler sheet.

2. The method for preparing the ultrafine wire saw according to claim 1, characterized in that, In step S31, the brazing material and adhesive are placed in a vacuum mixer and stirred evenly for at least five minutes. The total amount of brazing material and adhesive shall not exceed 0.5 kg.

3. The method for preparing the ultrafine wire saw according to claim 1, characterized in that, In step S32, a rolling mill is used to roll the brazing filler sheet to a predetermined thickness, the thickness of which is 1.1 to 1.6 times the diameter of the diamond particle.

4. The method for preparing the ultrafine wire saw according to claim 1, characterized in that, In step S4, diamond brazing blocks (2) are bonded to the high-temperature resistant wire rope (1) using glue, and multiple diamond brazing blocks (2) are arranged along the length of the high-temperature resistant wire rope (1).

5. The method for preparing the ultrafine wire saw according to claim 1, characterized in that, In step S4, natural drying is used, and the drying time is eight hours.

6. The method for preparing the ultrafine wire saw according to claim 1, characterized in that, The high-temperature resistant wire rope (1) with diamond brazing material block (2) bonded in step S4 is placed in an oven for drying. The drying time is two hours and the drying temperature is 70°C.

7. The method for preparing the ultrafine wire saw according to claim 1, characterized in that, The brazing in step S5 is performed using vacuum furnace brazing or continuous brazing, and the brazing temperature is 900-1000℃.

8. The method for preparing the ultrafine wire saw according to claim 1, characterized in that, The high-temperature resistant wire rope (1) is a single-strand rope or a multi-strand rope, and the outer diameter of the high-temperature resistant wire rope (1) is 0.1 to 2.5 mm.

9. The method for preparing the ultrafine wire saw according to claim 1, characterized in that, The outer diameter of the ultrafine wire saw in step S5 is 1-4 mm.

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