Drawing processing method of diamond wire bus

Abstract

The invention belongs to the technical field of diamond wire production, and particularly relates to a drawing machining method of a diamond wire bus, a steel wire is subjected to multi-pass drawing through a polycrystalline die and a single crystal die, the number proportion of the polycrystalline die and the single crystal die is set to be (15-16): (15-16), and a replaced abraded die is repaired. And a chamfer between the sizing area and the outlet area is polished and shaped through a reverse drawing process. The whole die change period of the wire drawing die is effectively prolonged, the die cost for production is reduced, and the production quality is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of diamond wire production, and in particular relates to a drawing method for a diamond wire mother bar. Background Art

[0002] During the production process of diamond wire busbar, the wire (steel wire or tungsten wire) is drawn multiple times through the drawing die in the wire drawing machine to make its size reach the production requirements of the diamond wire busbar. At present, the drawing dies in the wire drawing machine are mostly arranged in sequence of tungsten steel die + polycrystalline die + single crystal die. Among them, the tungsten steel die is low in price, but the surface smoothness of the steel wire after drawing cannot be guaranteed during the drawing process, and it is easy to wear and the replacement frequency is high. Therefore, it is mostly set in the front drawing pass. Due to the large number of tungsten steel dies and frequent replacement, the die is replaced when the die wears and the drawing size cannot be guaranteed. Usually, the dies of the entire wire drawing machine are replaced at the same time. This results in an overall replacement cycle of the wire drawing machine die of three days during the continuous drawing process, with a high replacement frequency. In addition, the tungsten steel die has a high wear rate and can be repaired less times. The overall service life is short, and a large number of new dies need to be invested. Therefore, it will lead to the problem of high cost of the current die for diamond wire busbar production. Summary of the invention

[0003] The present invention aims to solve the problem that in the existing production process of diamond wire busbar, the tungsten steel mold is easy to wear, resulting in a small number of repairs and frequent replacements, which leads to a relatively high cost of the mold for diamond wire busbar production as a whole. A drawing processing method for diamond wire busbar is provided. The method adopts a polycrystalline mold + a single crystal mold to cancel the tungsten steel mold, extends the mold replacement cycle, and effectively reduces the cost of the mold for diamond wire busbar production by grinding and repairing the worn mold and replacing the previous mold.

[0004] In order to achieve the above object, the technical solution of the present invention is: A method for drawing a diamond wire busbar comprises the following steps: In the first wire drawing step, the wire to be processed is drawn by using a first die set, the diameter of the wire to be processed is 0.4-0.5 mm, the first die set includes a plurality of first dies, the core material of the first die is polycrystalline diamond, and the core material of the first die is polycrystalline diamond, which effectively prolongs the die replacement cycle.

[0005] In the second wire drawing step, the wire after the first wire drawing step is drawn using the second die set and the third die set. After the wire drawing is completed, the diameter of the wire is 0.03-0.04mm. The second die set and the third die set both include a plurality of second dies. The core material of the second die is single crystal diamond, which effectively ensures the surface smoothness of the drawn steel wire.

[0006] The quantity ratio of the first mold and the second mold is (15-16): (15-16), the first mold and the second mold are arranged in descending order according to the diameter of the sizing zone, the ratio of the cross-sectional area of ​​the sizing zone between two adjacent molds is α, 0.8≤α≤0.9, the first mold and the second mold are replaced when the core wear size of the first mold and the second mold is 0.0005mm, and the replaced mold is repaired.

[0007] Preferably, the first mold group includes 16 first molds, the second mold group includes 8 second molds, and the third mold group includes 8 second molds.

[0008] Preferably, the first die and the second die both comprise an inlet lubrication zone, a compression zone, a sizing zone and an outlet zone.

[0009] Preferably, during the continuous drawing process, the mold change cycle of the third mold group is 3 days, the mold change cycle of the second mold group is 9 days, and the mold change cycle of the first mold group is 18 days. The mold change cycle means that during the continuous production process, the mold reaches its maximum specified wear size and needs to be replaced.

[0010] Preferably, the method further comprises repairing the replaced mold, wherein the mold repairing comprises the following steps: In the shaping step, the chamfer between the sizing area and the outlet area is polished and shaped by the reverse drawing process, and the compression area of ​​the mold is polished and shaped by the forward drawing process. The reverse drawing process is combined with the forward drawing process to effectively ensure the shaping quality of the mold core.

[0011] In the polishing step, the inlet lubrication area, the compression area, the chamfer between the sizing area and the outlet area of ​​the die and the outlet area are polished by a positive drawing process; In the sizing step, the sizing area of ​​the mold is polished to determine the diameter size of the sizing area, which is usually the diameter size of the sizing area of ​​the previous mold of the mold.

[0012] The wire material refers to steel wire or tungsten wire used for the production of diamond wire busbar. The diamond wire busbar is obtained by drawing the wire material, and the diamond wire busbar is subsequently electroplated and sanded to obtain a diamond wire product.

[0013] Through the above technical solution, the beneficial effects of the present invention are: 1. The present invention optimizes the diamond wire drawing die combination into a polycrystalline die + a single crystal die, thereby extending the single use cycle of the die, reducing the wear of the die during a single use, and effectively reducing the die cost.

[0014] 2. The present invention adopts a polycrystal mold + a single crystal mold to eliminate the use of a tungsten steel mold, thereby reducing the mold consumption of the diamond wire busbar by about 50% during the production process. Since the purchase cost of the polycrystal mold is higher than that of the tungsten steel mold, the mold cost and mold consumption do not decrease in the same proportion, and the overall mold cost decreases by about 30%.

[0015] 3. The present invention uses the reverse drawing process to grind and shape the chamfered position between the exit area and the sizing area during mold repair, while other processes still use the forward drawing process, which makes it easier to produce the ring and the ring diameter is stable during the mold application process. On the basis of ensuring the overall repair effect, the shaping and repair quality of the chamfered position between the exit area and the sizing area of ​​the mold is effectively improved, thereby ensuring the finished product quality of the diamond wire busbar production. DETAILED DESCRIPTION

[0016] The present invention will be further described below in conjunction with specific embodiments: This embodiment provides a method for drawing a diamond wire busbar, comprising the following steps: In the first wire drawing step, a wire to be processed is drawn by using a first die set, wherein the diameter of the wire to be processed is 0.4-0.5 mm, and the first die set comprises a plurality of first dies, wherein the core material of the first die is polycrystalline diamond.

[0017] A second wire drawing step, using a second die set and a third die set to draw the wire after the first wire drawing step, wherein the diameter of the wire after the wire drawing is 0.03-0.04 mm, the second die set and the third die set both include a plurality of second dies, and the core material of the second die is single crystal diamond; The quantity ratio of the first mold and the second mold is (15-16): (15-16), the first mold and the second mold are arranged in descending order according to the diameter of the sizing zone, and the ratio of the cross-sectional area of ​​the sizing zone between two adjacent molds is recorded as α, 0.8≤α≤0.9. Since the maximum processable size of the sizing zone of the single crystal mold is 0.13mm, the single crystal mold can be used for drawing only when the size reaches 0.13mm or less after the steel wire is drawn multiple times through the polycrystalline mold, and the surface smoothness of the produced steel wire is ensured by drawing with the single crystal mold. The first mold and the second mold are replaced when the core wear size is 0.0005mm, and the replaced mold is repaired.

[0018] The first die and the second die each include an inlet lubrication zone, a compression zone, a sizing zone, and an outlet zone.

[0019] Taking the production process of 0.03mm diamond wire busbar as an example, the mold chain is designed to be 32 molds. The existing technology adopts 16 tungsten steel molds, 8 polycrystalline molds, and 8 single crystal molds. Under uninterrupted continuous production conditions, the mold change cycle of the tungsten steel molds and the single crystal molds is 3 days. Considering the labor and time costs in the mold change process, all 32 molds are usually replaced every three days.

[0020] In this embodiment, the first mold group includes 16 first molds, the second mold group includes 8 second molds, and the third mold group includes 8 second molds.

[0021] During the continuous drawing process, the mold change cycle of the third mold group is 3 days, the mold change cycle of the second mold group is 9 days, and the mold change cycle of the first mold group is 18 days.

[0022] Under uninterrupted continuous production conditions, the mold change cycle is as follows: Production days (units / day) Mold change settings 0 Complete set of 32 molds 3 The third mold group 6 The third mold group 9 Second mold set + third mold set 12 The third mold group 15 The third mold group 18 Complete set of 32 molds According to testing, in the continuous drawing production process, the wear size of the 6-8 second dies located in the rear section of the third die group reaches 0.0005mm every three days, and they are replaced. Every 9 days, the wear size of the 6-8 second dies located in the rear section of the second die group reaches 0.0005mm, and they are replaced. Correspondingly, the first die of the first die group is replaced every 18 days.

[0023] It should be noted that as the drawing proceeds, the closer the die is to the rear section, the longer the steel wire is drawn, the easier it is to wear, and the higher the replacement frequency.

[0024] By adopting the mold combination of the present embodiment, under the above-mentioned trial production condition of mold change cycle, the produced diamond wire busbar is wound on the winding wheel, and 30 rounds of 7315km of diamond wire busbar are produced in 18 days, 287 rounds of A1+A3 quality are 6577km, 2 rounds of change of coil are 492km, 0 rounds of broken wire, 1 round of 246km of surface unqualified are found, the qualified rate is 89.91%, the coil change rate is 6.73%, and the broken wire rate is 0, which has no obvious difference from the production data of the existing mold combination (i.e., the mold combination of 16 tungsten steel molds, 8 polycrystalline molds, and 8 single crystal molds).

[0025] At the same time, the consumption of diamond wire molds is reduced by about 50% compared with the existing mold combination. Combined with the cost of purchasing molds, the overall mold cost is reduced by about 30%.

[0026] The replaced mold is repaired, and the mold repair includes the following steps: In the shaping step, the chamfer between the sizing area and the outlet area is polished and shaped by the reverse drawing process, and the compression area of ​​the mold is polished and shaped by the forward drawing process.

[0027] By adopting the method of combining reverse drawing with forward drawing, the shaping effect of the chamfer position between the sizing area and the exit area is effectively improved compared to the use of the forward drawing process while ensuring the shaping effect of the compression zone of the mold. When repairing a new mold, the forming and forming quality of the chamfer position between the sizing area and the exit area are guaranteed.

[0028] In the polishing step, the inlet lubrication area, the compression area, the chamfer between the sizing area and the outlet area of ​​the die and the outlet area are polished by a positive drawing process; Sizing step: grinding the sizing area of ​​the mold to determine the diameter of the sizing area; The forward drawing process is a drawing repair process in which the inlet lubrication area of ​​the mold core faces upward, and the reverse drawing process is a drawing repair process in which the outlet area of ​​the mold core faces upward.

[0029] It should be noted that the above-mentioned repair method of the wire drawing die for diamond wire busbar processing is suitable for the repair of different molds (such as single crystal molds, polycrystalline molds), that is, the repair of molds whose diameter in the sizing area increases by more than 0.0005mm due to wear during use, so that the mold meets the mold size requirements of the previous pass and can be reused.

[0030] At the same time, it is suitable for the processing and forming of new molds, that is, to repair the purchased mold blanks so that they meet the mold size requirements of the corresponding drawing passes.

[0031] The embodiments described above are only preferred embodiments of the present invention and are not intended to limit the scope of implementation of the present invention. Therefore, any equivalent changes or modifications made according to the structures, features and principles described in the patent scope of the present invention should be included in the scope of the patent application of the present invention.

Claims

1. A method for drawing a diamond wire busbar, characterized in that: The following steps are involved: A first wire drawing step, using a first die set to draw the wire to be processed, wherein the diameter of the wire to be processed is 0.4-0.5 mm, the first die set comprises a plurality of first dies, and the core material of the first die is polycrystalline diamond; A second wire drawing step, using a second die set and a third die set to draw the wire after the first wire drawing step, wherein the diameter of the wire after the wire drawing is 0.03-0.04 mm, the second die set and the third die set both include a plurality of second dies, and the core material of the second die is single crystal diamond; The quantity ratio of the first mold and the second mold is (15-16): (15-16), the first mold and the second mold are arranged in descending order according to the diameter of the sizing zone, the ratio of the cross-sectional area of ​​the sizing zone between two adjacent molds is α, 0.8≤α≤0.9, and the first mold and the second mold are replaced when the core wear size of the mold is 0.0005mm.

2. The method for drawing a diamond wire busbar according to claim 1, characterized in that: The first mold group includes 16 first molds, the second mold group includes 8 second molds, and the third mold group includes 8 second molds.

3. The method for drawing a diamond wire busbar according to claim 1, characterized in that: The first die and the second die each include an inlet lubrication zone, a compression zone, a sizing zone, and an outlet zone.

4. The method for drawing a diamond wire busbar according to claim 1, characterized in that: During the continuous drawing process, the mold change cycle of the third mold group is 3 days, the mold change cycle of the second mold group is 9 days, and the mold change cycle of the first mold group is 18 days.

5. A method for drawing a diamond wire busbar according to any one of claims 1 to 4, characterized in that: The replaced mold is repaired, and the mold repair includes the following steps: In the shaping step, the chamfer between the sizing area and the outlet area is polished and shaped by the reverse drawing process, and the compression area of ​​the mold is polished and shaped by the forward drawing process; In the polishing step, the inlet lubrication area, the compression area, the chamfer between the sizing area and the outlet area of ​​the die and the outlet area are polished by a positive drawing process; In the sizing step, the sizing area of ​​the mold is polished to determine the diameter size of the sizing area.