Fretsaw with waveform height consistency structure and production method thereof

Abstract

The invention belongs to the technical field of fretsaw production, and particularly relates to a fretsaw with a waveform height consistency structure and a production method of the fretsaw, and the production method comprises the following steps: drawing a high-carbon steel wire rod to form a steel wire with a smaller diameter; carrying out heat treatment processing and drawing processing on the steel wire in sequence to form a thin wire with a smaller diameter; carrying out heat treatment and electroplating procedures on the filaments in sequence to obtain brass-plated filaments; drawing the brass-plated thin wire to form a cutting steel wire with a smaller diameter; a plurality of cutting steel wires are stranded and processed to obtain a steel wire rope, and then the steel wire rope is untwisted into a plurality of independent cutting steel wires with uniform and consistent spiral deformation to serve as fret saws; according to the fretsaw production method, the produced fretsaw has a wave-shaped structure different from that of a traditional fretsaw, the wave-shaped structure is completely uniform and consistent in the direction of the steel wire, and it is guaranteed that the consistent and reliable mortar carrying capacity and cutting capacity are achieved in any direction.

Description

Technical Field

[0001] The invention belongs to the technical field of wire saw production, and in particular relates to a wire saw with a waveform highly consistent structure and a production method thereof. Background Art

[0002] Wire saws are essential consumables in multi-wire cutting and are widely used in cutting hard and brittle materials. Especially when the semiconductor industry adopts multi-wire cutting of wafers, the mainstream process is multi-wire cutting with wire saws as auxiliary materials. The existing wire saws are of two types: straight wire and structured wire. During the cutting process of the wire saw, metal wire (mainly steel wire) is used to carry mortar containing hard particles to grind the cut parts.

[0003] For straight wire, since there is no curved waveform, the ability to carry mortar is relatively poor, and the cutting ability and cutting efficiency are relatively poor. However, the structural wire has a curved waveform, which can better carry mortar, and has better cutting ability and cutting efficiency. The current production method of the structural wire is as shown in the attached Figure 1 As shown, two sets of paired gears are used to extrude and deform the steel wire to obtain a structural wire saw with a certain waveform. However, this processing method is destined to make the waveform of the wire saw uneven along the radial direction of the steel wire. The waveform only appears on the plane rolled by the gears, and the structural deformation points of the wire saw are only concentrated in the tiny local area where the steel wire contacts the gears. During multi-wire slicing, the metal wire that moves rapidly along the axial direction of the steel wire will inevitably rotate during operation, so the unevenness along the radial direction of the steel wire will lead to inconsistent cutting effects.

[0004] And under this processing method, the produced structural wire has the following problems:

[0005] ① Two sets of vertically distributed gears are used to extrude the steel wire to obtain waveforms distributed on two planes, rather than waveforms uniformly distributed 360 degrees along the radial direction of the steel wire;

[0006] ② The two sets of gears are arranged in sequence. After the first set of gears rolls out a set of waveforms, the second set of gears rolls out a second set of waves perpendicular to the plane of the first set of waves. If the steel wire rotates, the two sets of waves are easily rolled and overlapped, thus forming a plane wave rather than a three-dimensional waveform.

[0007] To this end, we propose a wire saw with a waveform highly consistent structure and a production method thereof. Summary of the invention

[0008] The purpose of the present invention is to provide a wire saw with a waveform highly consistent structure and a production method thereof, so as to solve the problems existing in the background technology.

[0009] In order to achieve the above technical objectives, the technical solution adopted by the present invention is as follows:

[0010] A method for producing a wire saw having a waveform highly consistent structure, the method comprising the following steps:

[0011] Step S1: drawing the high carbon steel wire rod to form a steel wire with a smaller diameter;

[0012] Step S2: the steel wire obtained in the above steps is subjected to heat treatment and drawing in sequence to further form a filament with a smaller diameter;

[0013] Step S3: subjecting the filament to a heat treatment and an electroplating process to obtain a brass-plated filament;

[0014] Step S4: drawing the brass-plated filament to form a cutting wire with a smaller diameter;

[0015] Step S5: The plurality of cutting steel wires are stranded through a stranding machine, and the pay-off tension is controlled during the stranding process to obtain a steel wire rope formed by winding the plurality of cutting steel wires, and then the steel wire rope is re-twisted through an untwister into a plurality of individual cutting steel wires with uniform spiral deformation. The obtained cutting steel wire with uniform spiral deformation is used as a wire saw.

[0016] In the step S1, the carbon content of the high carbon steel wire rod is above 0.7%, preferably above 0.8%.

[0017] The step S1 specifically includes the following steps:

[0018] Step S1.1: Lay out the high carbon steel wire rod, first remove most of the oxide layer on the wire rod surface by mechanical descaling, then remove the remaining oxide layer on the wire rod surface by hydrochloric acid pickling, and finally apply boron on the wire rod surface;

[0019] Step S1.2: Through multiple large-drawing processes, the wire rod is drawn into a steel wire with a smaller diameter using a dry drawing machine.

[0020] The step S2 specifically includes the following steps:

[0021] Step S2.1: subjecting the steel wire obtained in step S1 to a degreasing process to remove excess borax and soap powder on the surface of the steel wire;

[0022] Step S2.2: heat-treating the degreased steel wire in a gas furnace to heat the steel wire to austenitization, and then quenching the steel wire in a water bath with temperature control to obtain a sorbitized steel wire;

[0023] Step S2.3: pickling the steel wire to remove the oxide scale on the surface, and then washing the steel wire again with water to remove the residual acid on the surface of the steel wire;

[0024] Step S2.4: pre-coating borax on the surface of the steel wire and passing through a drying oven to ensure that the pre-coated borax on the surface of the steel wire remains dry;

[0025] Step S2.5: Through multiple intermediate drawing processes, the steel wire is drawn into a thin wire with a smaller diameter using a dry drawing machine.

[0026] The step S3 specifically comprises the following steps:

[0027] Step S3.1: subjecting the filament obtained in step S2 to a degreasing process to remove excess borax and soap powder on the surface of the steel wire;

[0028] Step S3.2: heat-treating the degreased filaments in a gas furnace until they are austenitized, and then quenching them in a water bath to obtain filaments with a sorbite structure;

[0029] Step S3.3: pickling the filaments to remove the oxide scale on the surface, and then washing the filaments again with water to remove the residual acid on the surface of the filaments;

[0030] Step S3.4: The filament is firstly plated with copper by a copper plating process, and then the residual copper plating liquid is removed by water washing, and then the filament is plated with zinc by a zinc plating process, and then the copper-zinc plated filament is passed through a medium frequency thermal diffusion device to thermally diffuse the copper-zinc on the surface of the filament to obtain a brass coating with a copper content of 70%;

[0031] Step S3.5: The brass-plated filament is first cooled by water cooling, and then the brass-plated filament is pickled by phosphoric acid to remove the zinc oxide of the brass coating, and then the brass-plated filament is passed through a high-temperature soap immersion liquid to pre-lubricate the surface of the brass-plated filament, and finally the surface of the brass-plated filament is sucked dry by an air suction plate.

[0032] The step S4 is specifically as follows:

[0033] Through multiple wet drawing processes, the brass-plated wire is drawn into a smaller diameter cutting wire using a wet drawing machine.

[0034] The wire saw production method proposed in the present invention produces a wire saw with a waveform structure different from that of a traditional wire saw. This waveform structure is completely uniform along the direction of the steel wire, ensuring that when used as a wire saw, it has consistent and reliable mortar carrying and cutting capabilities in any orientation. It also has the advantages of easy processing and high production efficiency of being able to process multiple wire saws at one time. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The present invention is further illustrated by means of the non-limiting examples given in the accompanying drawings.

[0036] Figure 1 It is a brief schematic diagram of the existing processing methods of the structural line;

[0037] Figure 2 It is a schematic diagram of the main steps of the present invention;

[0038] Figure 3 It is a schematic diagram of twisting and untwisting of the cut steel wire of the present invention; DETAILED DESCRIPTION

[0039] In order to enable those skilled in the art to better understand the present invention, the technical solution of the present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0040] A method for producing a wire saw having a waveform highly consistent structure, the method comprising the following steps:

[0041] Step S1: Drawing the high carbon steel wire rod to form a steel wire with a smaller diameter, specifically comprising the following steps:

[0042] Step S1.1: Lay out the high carbon steel wire rod, first remove most of the oxide layer on the wire rod surface by mechanical descaling, then remove the remaining oxide layer on the wire rod surface by hydrochloric acid pickling, and finally apply boron on the wire rod surface;

[0043] Step S1.2: Through multiple large-drawing processes, the wire rod is drawn into a steel wire with a smaller diameter using a dry drawing machine.

[0044] The carbon content of the high carbon steel wire rod is above 0.7%, preferably above 0.8%.

[0045] Step S2: The steel wire obtained in the above steps is subjected to heat treatment and drawing in sequence to further form a filament with a smaller diameter, which specifically includes the following steps:

[0046] Step S2.1: subjecting the steel wire obtained in step S1 to a degreasing process to remove excess borax and soap powder on the surface of the steel wire;

[0047] Step S2.2: heat-treating the degreased steel wire in a gas furnace to heat the steel wire to austenitization, and then quenching the steel wire in a water bath with temperature control to obtain a sorbitized steel wire;

[0048] Step S2.3: pickling the steel wire to remove the oxide scale on the surface, and then washing the steel wire again with water to remove the residual acid on the surface of the steel wire;

[0049] Step S2.4: pre-coating borax on the surface of the steel wire and passing through a drying oven to ensure that the pre-coated borax on the surface of the steel wire remains dry;

[0050] Step S2.5: Through multiple intermediate drawing processes, the steel wire is drawn into a thin wire with a smaller diameter using a dry drawing machine.

[0051] Step S3: subjecting the filament to a heat treatment and an electroplating process to obtain a brass-plated filament, which specifically includes the following steps:

[0052] Step S3.1: subjecting the filament obtained in step S2 to a degreasing process to remove excess borax and soap powder on the surface of the steel wire;

[0053] Step S3.2: heat-treating the degreased filaments in a gas furnace until they are austenitized, and then quenching them in a water bath to obtain filaments with a sorbite structure;

[0054] Step S3.3: pickling the filaments to remove the oxide scale on the surface, and then washing the filaments again with water to remove the residual acid on the surface of the filaments;

[0055] Step S3.4: The filament is firstly plated with copper by a copper plating process, and then the residual copper plating liquid is removed by water washing, and then the filament is plated with zinc by a zinc plating process, and then the copper-zinc plated filament is passed through a medium frequency thermal diffusion device to thermally diffuse the copper-zinc on the surface of the filament to obtain a brass coating with a copper content of 70%;

[0056] Step S3.5: The brass-plated filament is first cooled by water cooling, and then the brass-plated filament is pickled by phosphoric acid to remove the zinc oxide of the brass coating, and then the brass-plated filament is passed through a high-temperature soap immersion liquid to pre-lubricate the surface of the brass-plated filament, and finally the surface of the brass-plated filament is sucked dry by an air suction plate.

[0057] Step S4: Drawing the brass-plated filament to form a cutting wire with a smaller diameter, specifically:

[0058] Through multiple wet drawing processes, the brass-plated wire is drawn into a smaller diameter cutting wire using a wet drawing machine.

[0059] Step S5: The plurality of cutting steel wires are stranded through a stranding machine, and the pay-off tension is controlled during the stranding process to obtain a steel wire rope formed by winding the plurality of cutting steel wires, and then the steel wire rope is re-twisted through an untwister into a plurality of individual cutting steel wires with uniform spiral deformation. The obtained cutting steel wire with uniform spiral deformation is used as a wire saw.

[0060] The examples are as follows:

[0061] First, a high-carbon steel wire rod with a diameter of 5.5 mm and a carbon content of 0.86% is processed into a filament with a diameter of 0.96 mm, the filament with a diameter of 0.96 mm is subjected to a sorbitization heat treatment and a layer of brass (copper-zinc alloy, wherein copper is 70%, zinc is 30%, and the weight of the coating on each kilogram of steel wire is 7 grams) is plated on the surface to obtain a 0.96 mm brass-plated filament, and the brass-plated filament is passed through a 23-pass wet drawing device to draw a cutting steel wire with a diameter of 0.13 mm;

[0062] Then, two or more 0.13mm cutting steel wires are twisted into ropes with a twisting device, with a twisting pitch of 5mm. Then, a twister rotating in the opposite direction of the twisting direction is used to untwist the wire rope into two cutting steel wires and collect them on the I-shaped wheels respectively. During the twisting process, the two cutting steel wires are entangled and squeezed with each other, and both obtain uniform spiral structural deformation, thereby obtaining a wire saw with a uniform spiral waveform.

[0063] The above production process is described in detail as follows:

[0064] ① Large drawing process: 5.5mm diameter wire rod pay-off → mechanical descaling to remove most of the oxide scale on the wire rod → hydrochloric acid washing to remove the residual oxide scale on the wire rod → boron coating in borax tank → 6 passes of dry drawing to pull the 5.5mm wire rod to 2.8mm steel wire → wire rack winding;

[0065] The main equipment used in the large drawing process is a dry wire drawing machine, which is a prior art and will not be described in detail here;

[0066] ②Heat treatment process: pay out the wire rack with the above steel wire of 2.8mm diameter → pass the steel wire through the degreasing tank (remove the excess borax and soap powder on the surface of the steel wire) → pass the steel wire through the gas furnace to heat the steel wire to austenitization → quench in water bath to obtain sorbitization steel wire → pass the steel wire through the pickling tank to wash off the surface oxide scale → pass the steel wire through the water washing tank to wash off the residual acid on the surface of the steel wire → pass the steel wire through the borax tank to pre-coat a layer of borax on the surface of the steel wire → pass the steel wire through the drying box to ensure that the borax on the surface of the steel wire is dry → wind up to obtain the heat-treated steel wire with a diameter of 2.8mm;

[0067] ③ Intermediate drawing process: pay out the wire rack of the heat-treated steel wire with a diameter of 2.8 mm → draw the heat-treated steel wire with a diameter of 2.8 mm into a thin wire with a diameter of 0.96 mm through 10 intermediate drawing equipment → collect it on the WS1000 I-shaped wheel;

[0068] The main equipment used in the middle drawing process is a dry wire drawing machine, which is a prior art and will not be described in detail here;

[0069] ④ Heat treatment and copper plating process: pay out the 0.96mm diameter filament collected on the WS1000 I-shaped wheel → pass the filament through the degreasing tank (remove excess borax and soap powder on the surface of the filament) → heat the filament in a gas furnace to austenitize → quench in a water bath to obtain a filament with a sorbite structure → pass the filament through the pickling tank to wash off the oxide scale on the surface → pass the filament through the water rinsing tank to wash off the residual acid on the surface of the filament → pass through the copper plating tank to copper the surface of the filament → pass through the water rinsing tank to clean the residual copper plating liquid on the surface of the filament → pass through the galvanizing tank The surface of the filament is galvanized → The copper-zinc-plated filament is passed through the medium frequency thermal diffusion equipment to make the copper-zinc thermal diffusion on the surface of the filament obtain a brass coating with a copper content of 70%. The brass layer on each 1kg of filament weighs 7g → The brass-plated filament continues to be cooled in the water cooling tank → The brass-plated filament passes through the phosphoric acid tank to wash off the ZnO (zinc oxide) on the brass layer → The brass-plated filament passes through the high-temperature soap immersion liquid, and a layer of lubricating liquid is pre-coated on the filament, and then the surface of the filament is dried through the suction plate → The brass-plated filament with a diameter of 0.96mm is collected on the WS550 I-shaped wheel by the wire take-up machine;

[0070] ⑤ Wet drawing process: pay-off of 0.96mm diameter brass-plated fine wire → 23 passes of wet drawing machine to obtain 0.13mm diameter cutting steel wire → 0.13mm diameter cutting steel wire is taken up on WS50 wet drawing take-up wheel;

[0071] The main equipment used in the wet drawing process is a wet drawing machine, which is a prior art and will not be described in detail here;

[0072] ⑥ Forming process: two WS50 I-shaped wheels equipped with 0.13mm cutting wires are used to pay off the wires, and the pay-off tension is controlled → the two cutting wires are twisted in a twisting machine → the twisted wire rope is untwisted again through an untwister to be two separate deformed cutting wires → the wires are taken up separately to obtain two cutting wires with uniform spiral deformation as a wire saw.

[0073] The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with the technology may modify or change the above embodiments without violating the spirit and scope of the present invention. Therefore, all equivalent modifications or changes made by those with ordinary knowledge in the technical field without departing from the spirit and technical ideas disclosed by the present invention should still be covered by the claims of the present invention.

Claims

1. A method for producing a wire saw having a waveform highly consistent structure, Features: The production method comprises the following steps: Step S1: drawing the high carbon steel wire rod to form a steel wire with a smaller diameter; Step S2: The steel wire obtained in the above steps is subjected to heat treatment and drawing in sequence to further form a filament with a smaller diameter; Step S3: subjecting the filament to a heat treatment and an electroplating process to obtain a brass-plated filament; Step S4: drawing the brass-plated filament to form a cutting wire with a smaller diameter; Step S5: The plurality of cutting steel wires are stranded through a stranding machine, and the pay-off tension is controlled during the stranding process to obtain a steel wire rope formed by winding the plurality of cutting steel wires, and then the steel wire rope is re-twisted through an untwister into a plurality of individual cutting steel wires with uniform spiral deformation. The obtained cutting steel wire with uniform spiral deformation is used as a wire saw.

2. A method for producing a wire saw having a waveform highly consistent structure according to claim 1, Features: In the step S1, the carbon content of the high carbon steel wire rod is above 0.7%, preferably above 0.8%.

3. A method for producing a wire saw having a waveform highly consistent structure according to claim 2, Features: The step S1 specifically includes the following steps: Step S1.1: Lay out the high carbon steel wire rod, first remove most of the oxide layer on the wire rod surface by mechanical descaling, then remove the remaining oxide layer on the wire rod surface by hydrochloric acid pickling, and finally apply boron on the wire rod surface; Step S1.2: Through multiple large-drawing processes, the wire rod is drawn into a steel wire with a smaller diameter using a dry drawing machine.

4. The method for producing a wire saw having a waveform highly consistent structure according to claim 3, Features: The step S2 specifically includes the following steps: Step S2.1: subjecting the steel wire obtained in step S1 to a degreasing process to remove excess borax and soap powder on the surface of the steel wire; Step S2.2: heat-treating the degreased steel wire in a gas furnace to heat the steel wire to austenitization, and then quenching the steel wire in a water bath with temperature control to obtain a sorbitized steel wire; Step S2.3: pickling the steel wire to remove the oxide scale on the surface, and then washing the steel wire again with water to remove the residual acid on the surface of the steel wire; Step S2.4: pre-coating borax on the surface of the steel wire and passing through a drying oven to ensure that the pre-coated borax on the surface of the steel wire remains dry; Step S2.5: Through multiple intermediate drawing processes, the steel wire is drawn into a thin wire with a smaller diameter using a dry drawing machine.

5. The method for producing a wire saw having a waveform highly consistent structure according to claim 4, Features: The step S3 specifically comprises the following steps: Step S3.1: subjecting the filament obtained in step S2 to a degreasing process to remove excess borax and soap powder on the surface of the steel wire; Step S3.2: heat-treating the degreased filaments in a gas furnace until they are austenitized, and then quenching them in a water bath to obtain filaments with a sorbite structure; Step S3.3: pickling the filaments to remove the oxide scale on the surface, and then washing the filaments again with water to remove the residual acid on the surface of the filaments; Step S3.4: The filament is firstly plated with copper by a copper plating process, and then the residual copper plating liquid is removed by water washing, and then the filament is plated with zinc by a zinc plating process, and then the copper-zinc plated filament is passed through a medium frequency thermal diffusion device to thermally diffuse the copper-zinc on the surface of the filament to obtain a brass coating with a copper content of 70%; Step S3.5: The brass-plated filament is first cooled by water cooling, and then the brass-plated filament is pickled by phosphoric acid to remove the zinc oxide of the brass coating, and then the brass-plated filament is passed through a high-temperature soap immersion liquid to pre-lubricate the surface of the brass-plated filament, and finally the surface of the brass-plated filament is sucked dry by an air suction plate.

6. A method for producing a wire saw having a waveform highly consistent structure according to claim 5, Features: The step S4 is specifically as follows: Through multiple wet drawing processes, the brass-plated wire is drawn into a smaller diameter cutting wire using a wet drawing machine.

7. A wire saw produced by the method for producing a wire saw with a waveform highly consistent structure according to any one of claims 1 to 6.

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