Small-diameter diamond wire saw and preparation method thereof

Abstract

The invention relates to the technical field of diamond wire saw preparation, in particular to a small-diameter diamond wire saw and a preparation method thereof. The small-diameter diamond wire saw comprises a steel wire rope and a plurality of sets of beads fixedly arranged on the steel wire rope in a sleeving mode, each set of beads comprises at least one thick ring and at least one thin ring, the outer diameters of the thick rings and the outer diameters of the thin rings are the same, the thickness of the thick rings is 2-5 times that of the thin rings, and the thick rings and the thin rings are arranged on the steel wire rope at intervals. And the thick rings and the thin rings of the plurality of groups of beads are fixedly connected with the steel wire rope through injection molding layers. According to the small-diameter diamond wire saw and the preparation method thereof, the thick ring and the thin ring adopt ring sheet structures, so that high cutting efficiency can be achieved while the service life of a product is ensured. And meanwhile, the small-diameter string bead does not contain a base body, so that the production process is simple, and the string bead is modularly produced by combining thickness and thickness, so that the consistency and durability of the product are greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of diamond wire saw preparation, and in particular to a small-diameter diamond wire saw and a preparation method thereof. Background Art

[0002] Diamond wire saw is a flexible superhard material tool, widely used in mining, stone processing, building and bridge demolition, marine salvage and other industries. The main function of diamond beads is to consolidate diamond abrasive grains and achieve efficient grinding during sawing.

[0003] The existing methods for preparing diamond wire saws mainly include sintering, brazing and electroplating. Diamond beads with a large diameter of 10mm-15mm are usually prepared by sintering and brazing. The sintering method uses the principle of powder metallurgy to evenly mix or granulate diamond and selected matrix powder, but the sintering method requires sintering after combining with the matrix. Although the production efficiency is high and the process is simple, the diamond has low blade output and low cutting efficiency, and the size is large due to the matrix. The principle of the brazing method is to use the melting, infiltration, diffusion, and chemical interactions that occur at the interface of the abrasive, brazing material and matrix during brazing to generate a holding force on the diamond through the brazing material. This method makes the bonding strength between the diamond and the matrix high, the service life long, the diamond bead abrasive edge thickness is large, the chip capacity is large, the grinding temperature is low, and the cutting efficiency is high. Small diameter diamonds are usually manufactured by electroplating, but the coating of diamond abrasive grains consolidated by electroplating is too thin, and the coating has limited holding power on diamond abrasive grains, which easily causes diamond abrasive grains to fall off prematurely. At present, the main technical bottlenecks encountered in the production process of diamond beads, especially for beads below 5.0 mm, have to face problems such as high production cost, poor sharpness, and short bead life, which will greatly restrict the development of small diameter diamond beads. Summary of the invention

[0004] The purpose of the present invention is to overcome the above technical problems and provide a small-diameter diamond wire saw with strong versatility, long service life and good sharpness and a preparation method thereof.

[0005] To achieve the above-mentioned purpose, the technical solution adopted by the present invention is as follows: a small-diameter diamond wire saw, comprising a steel wire rope and a plurality of groups of beads fixedly sleeved on the steel wire rope, wherein the group of beads comprises at least one thick ring and at least one thin ring, the outer diameters of the thick ring and the thin ring are the same, and the thickness of the thick ring is 2-5 times the thickness of the thin ring, the thick ring and the thin ring are arranged at intervals on the steel wire rope, and the thick rings, the thin rings of the plurality of groups of beads are fixedly connected to the steel wire rope through an injection molding layer.

[0006] Furthermore, the outer diameter of the thick ring and the thin ring is 2-10 mm, and the inner diameter is 1-5 mm.

[0007] Furthermore, the thickness of the thick ring is 2-5 mm, and the thickness of the thin ring is 0.5-2.0 mm.

[0008] Furthermore, a set of beads includes a thick ring at the front end and a plurality of thin rings at the rear end, and the thick ring and the plurality of thin rings are arranged equidistantly.

[0009] Furthermore, the thick rings and thin rings of the beads are prepared from the following raw materials in percentage by weight, including: 70-85% FeCuCoNi alloy powder, 10-20% copper-tin alloy powder, 1-5% Cr powder, and 1-5% diamond powder.

[0010] Furthermore, the FeCuCoNi alloy powder is prepared from the following raw materials in weight percentage: Ni content in the pre-alloyed powder is 5-15%, Co content is 10-25%, Cu content is 5-15%, and Fe content is 60-70%.

[0011] Further, the diamond powder is mixed by the following weight percentages of diamond powder, including 20-40% of fine-grained diamond powder, 40-60% of medium-grained diamond powder, and 20-40% of coarse-grained diamond powder, and the diamond powder is 30#-100# mesh.

[0012] The preparation method of the small diameter diamond wire saw is to prepare any one of the small diameter diamond wire saws described above, and the specific steps are as follows:

[0013] Step 1: mixing: placing 70-85% by weight of FeCuCoNi alloy powder, 10-20% by weight of copper-tin alloy powder, 1-5% by weight of Cr powder, and 1-5% by weight of diamond powder in a mixer to obtain a mixture;

[0014] Step 2: granulation: adding the mixture into a granulator, then adding a granulating agent with a mass fraction of 1-3% of the mixture and mixing the mixture again, adding 3-5% alcohol with a mass fraction of the mixture into the granulator for granulation to obtain a cold pressed material;

[0015] Step 3: cold pressing: putting the cold pressed material into a cold press to press it into thick rings and thin rings of different thicknesses;

[0016] Step 4: sintering: placing the pressed thick ring and thin ring into a vacuum furnace for sintering;

[0017] Step five: molding. Brush glue on the steel wire rope, thread the sintered thick rings and thin rings into the rope in the required order, and use the corresponding mold for injection molding to form a beaded rope.

[0018] Furthermore, when preparing the FeCuCoNi alloy powder, the FeCoNi alloy powder is first prepared by an atomization method, and then Cu powder is added according to a proportion.

[0019] Furthermore, during the vacuum furnace sintering in step 4, the sintering temperature is 800-1000° C., and the holding time is 50-80 min.

[0020] From the above description of the present invention, it can be seen that compared with the prior art, the small-diameter diamond wire saw and the preparation method thereof provided by the present invention have the following beneficial effects: the small-diameter diamond wire saw beads adopt a combination of thick rings and thin rings, and the thick rings and the thin rings adopt a ring-shaped structure, which can adjust and change the structure of the product according to the cutting object of the product and the requirements for product performance, and can be convenient for mass production, thereby greatly reducing the production cost. The thick ring ensures sufficient support for the product during the cutting process, thereby ensuring the durability of the product, and the rear-end thin ring structure improves the sharpness. The thinner the thickness of the thin ring and the greater the number, the better the sharpness. The small-diameter diamond wire saw beads provided by the present invention adopt matrix-free beads, which can greatly extend the service life of the product. The production process of matrix-free beads is simple and the production cost is low. At the same time, since there is no volume occupied by the matrix, it is conducive to the preparation of diamond wire saws with a small diameter of less than 5.0 mm. The diamonds on the prepared beads are distributed in multiple layers, thereby greatly improving the consistency and durability of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a structural schematic diagram of a specific embodiment 1;

[0022] Figure 2 It is a cross-sectional schematic diagram of a specific embodiment 1. DETAILED DESCRIPTION

[0023] The technical solution of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0024] like Figure 1 , 2 As shown, a small diameter diamond wire saw comprises a steel wire rope 1, a plurality of sets of beads 2 and an injection molding layer 3;

[0025] A set of beads 2 includes at least one thick ring 21 and at least one thin ring 22, the outer diameters of the thick ring 21 and the thin ring 22 are the same, and the thickness of the thick ring 21 is 2-5 times the thickness of the thin ring 22, the thick ring 21 and the thin ring 22 are arranged on the steel wire rope 1 at intervals, and the thick rings 21 and the thin rings 22 of the multiple sets of beads 2 are fixedly connected to the steel wire rope 1 through the injection molding layer 3;

[0026] The outer diameter of the thick ring 21 and the thin ring 22 is 2-10mm, and the inner diameter is 1-5mm. The thickness of the thick ring 21 is 2-5mm, and the thickness of the thin ring 22 is 0.5-2.0mm. The inner diameter of the thick ring 21 and the thin ring 22 is 0.1-0.3mm larger than the diameter of the wire rope. A set of beads includes a thick ring 21 and multiple thin rings 22, and the thick ring 21 and multiple thin rings 22 are arranged equidistantly.

[0027] The thick ring 21 and the thin ring 22 of the beaded wire are prepared from the following raw materials in weight percentage, including: 70-85% FeCuCoNi alloy powder, 10-20% copper-tin alloy powder, 1-5% Cr powder, and 1-5% diamond powder. The FeCuCoNi alloy powder is prepared from the following raw materials in weight percentage, including: 5-15% Ni content in pre-alloyed powder, 10-25% Co content, 5-15% Cu content, and 60-70% Fe content.

[0028] The specific steps of preparing any of the above-mentioned small diameter diamond wire saws are as follows:

[0029] Step 1: mixing: 70-85% FeCuCoNi alloy powder, 10-20% copper-tin alloy powder, 1-5% Cr powder, and 1-5% diamond powder are placed in a mixer for mixing to obtain a mixture. When preparing the FeCuCoNi alloy powder, the FeCoNi alloy powder is first prepared by an atomization method, and then Cu powder is added according to the ratio. The Cu powder is crushed by an air flow crusher. The diamond powder is mixed with the following weight percentages of diamond powder, including 20-40% fine-grained diamond powder, 40-60% medium-grained diamond powder, and 20-40% coarse-grained diamond powder, and the diamond powder is 30#-100# mesh;

[0030] Step 2: granulation: adding the mixture into a granulator, then adding a granulating agent with a mass fraction of 1-3% of the mixture and mixing the mixture again, adding 3-5% alcohol with a mass fraction of the mixture into the granulator for granulation to obtain a cold pressed material;

[0031] Step 3: cold pressing: putting the cold pressed material into a cold press to press it into thick rings and thin rings of different thicknesses;

[0032] Step 4: sintering: placing the pressed thick ring and thin ring into a vacuum furnace for sintering at a sintering temperature of 800-1000°C and a holding time of 50-80 minutes;

[0033] Step five: molding. Brush glue on the steel wire rope, thread the sintered thick rings and thin rings into the rope in the required order, and use the corresponding mold for injection molding to form a beaded rope. Specific embodiment one:

[0035] like Figure 1 , 2 As shown, a small diameter diamond wire saw comprises a steel wire rope 1, multiple groups of beads 2 and an injection molding layer 3; one group of beads 2 comprises a thick ring 21 and three thin rings 22, the inner diameter of the thick ring 21 and the thin ring 22 is 2.2 mm, the outer diameter is 4.5 mm, the thickness of the thick ring 21 is 3.0 mm, the thickness of the thin ring 22 is 1.0 mm, the thickness of the thick ring 21 is 3 times the thickness of the thin ring 22, the thick ring 21 and the thin ring 22 are arranged at intervals on the steel wire rope 1, the thick rings 21 and the thin rings 22 of the multiple groups of beads 2 are fixedly connected to the steel wire rope 1 through the injection molding layer 3, the diameter of the steel wire rope is 2.0 mm, one group of beads comprises a thick ring 21 and multiple thin rings 22, and the thick ring 21 and the multiple thin rings 22 are arranged equidistantly.

[0036] The thick ring 21 and the thin ring 22 of the beaded wire are prepared from the following raw materials in weight percentage, including: 82% FeCuCoNi alloy powder, 15% copper-tin alloy powder, 1.5% Cr powder, and 1.5% diamond powder. The FeCuCoNi alloy powder is prepared from the following raw materials in weight percentage, including: 10% Ni content, 20% Co content, 10% Cu content, and 60% Fe content in the pre-alloyed powder.

[0037] The specific steps of preparing any of the above-mentioned small diameter diamond wire saws are as follows:

[0038] Step 1: mixing: 82% FeCuCoNi alloy powder, 15% copper-tin alloy powder, 1.5% Cr powder, and 1.5% diamond powder are placed in a mixer for mixing to obtain a mixture. When preparing the FeCuCoNi alloy powder, the FeCoNi alloy powder is first prepared by an atomization method, and then Cu is added and crushed by an air flow crusher. The diamond powder includes 30% fine-grained diamond powder, 50% medium-grained diamond powder, and 20% coarse-grained diamond powder. The coarse-grained diamond powder is 30 / 40 mesh, the medium-grained diamond powder is 40 / 50#, and the fine-grained diamond powder is 50 / 60#;

[0039] Step 2: granulation: add the mixture into a granulator and mix for 100 minutes, then add 2% of the mixture by mass of an acrylic resin granulating agent and mix the mixture again for 30 minutes, add 5% of the mixture by mass of alcohol into the granulator at a speed of 1200 rpm for granulation to obtain a cold pressed material;

[0040] Step 3: cold pressing: putting the cold pressed material into a cold press machine and pressing it into thick rings and thin rings. The cold pressed outer diameter of the thick rings and thin rings is 4.5 mm, the inner diameter is 2.2 mm, the thickness of the thick ring is 3.0 mm, and the thickness of the thin ring is 1.0 mm.

[0041] Step 4: sintering: placing the pressed thick ring and thin ring into a vacuum furnace for sintering. The sintering temperature of the vacuum furnace is 800-1000°C and the holding time is 50-80 minutes.

[0042] Step five: molding. Brush glue on the steel wire rope, thread the sintered thick rings and thin rings into the rope in the required order, and use the corresponding mold for injection molding to form a beaded rope.

[0043] The small diameter diamond wire saw beads 2 are in the form of a combination of thick rings 21 and thin rings 22. The thick rings 21 and thin rings 22 are in a ring-shaped structure. The structure of the product can be adjusted according to the cutting object of the product and the requirements for product performance. It is also convenient for mass production, thereby greatly reducing production costs. The thick ring 21 ensures sufficient support for the product during the cutting process, thereby ensuring the durability of the product. The rear end thin ring 22 structure improves sharpness. The thinner the thin ring 22 is and the more the number is, the better the sharpness is.

[0044] The above-mentioned small-diameter diamond wire saw beads adopt matrix-free beads, which can greatly extend the service life of the product. The production process of matrix-free beads is simple and the production cost is low. At the same time, since there is no volume occupied by the matrix, the preparation of small-diameter diamond wire saws less than 5.0 mm can be achieved. The diamonds on the prepared beads 2 are distributed in multiple layers, thereby greatly improving the consistency and durability of the product.

[0045] The above are only some specific implementation methods of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial changes to the present invention using this concept shall be deemed as an infringement of the protection scope of the present invention.

Claims

1. A small diameter diamond wire saw, comprising a steel wire rope and a fixed sleeve with multiple sets of beads on the steel wire rope, characterized in that: The group of beads includes at least one thick ring and at least one thin ring, the outer diameters of the thick ring and the thin ring are the same, and the thickness of the thick ring is 2-5 times the thickness of the thin ring, the thick ring and the thin ring are arranged at intervals on the steel wire rope, and the thick rings, thin rings and the steel wire rope of the multiple groups of beads are fixedly connected by an injection molding layer.

2. The small diameter diamond wire saw according to claim 1, characterized in that: The thick ring and the thin ring have an outer diameter of 2-10 mm and an inner diameter of 1-5 mm.

3. The small diameter diamond wire saw according to claim 1 or 2, characterized in that: The thickness of the thick ring is 2-5 mm, and the thickness of the thin ring is 0.5-2.0 mm.

4. The small diameter diamond wire saw according to claim 1, characterized in that: The group of beads comprises a thick ring at the front end and a plurality of thin rings at the rear end, and the thick ring and the plurality of thin rings are arranged equidistantly.

5. The small diameter diamond wire saw according to claim 1, characterized in that: The thick ring and the thin ring of the beaded string are prepared from the following raw materials in percentage by weight, including: 70-85% of FeCuCoNi alloy powder, 10-20% of copper-tin alloy powder, 1-5% of Cr powder and 1-5% of diamond powder.

6. The small diameter diamond wire saw according to claim 5, characterized in that: The FeCuCoNi alloy powder is prepared from the following raw materials in weight percentage: Ni content in the pre-alloyed powder is 5-15%, Co content is 10-25%, Cu content is 5-15%, and Fe content is 60-70%.

7. The small diameter diamond wire saw according to claim 5, characterized in that: The diamond powder is mixed by the following weight percentages of diamond powder, including 20-40% of fine-grained diamond powder, 40-60% of medium-grained diamond powder, and 20-40% of coarse-grained diamond powder, and the diamond powder is 30#-100# mesh.

8. A method for preparing a small diameter diamond wire saw, characterized in that: The specific steps of preparing any of the above-mentioned small diameter diamond wire saws are as follows: Step 1: mixing: placing 70-85% by weight of FeCuCoNi alloy powder, 10-20% by weight of copper-tin alloy powder, 1-5% by weight of Cr powder, and 1-5% by weight of diamond powder in a mixer to obtain a mixture; Step 2: granulation: adding the mixture into a granulator, then adding a granulating agent with a mass fraction of 1-3% of the mixture and mixing the mixture again, adding 3-5% alcohol with a mass fraction of the mixture into the granulator for granulation to obtain a cold pressed material; Step 3: cold pressing: putting the cold pressed material into a cold press to press it into thick rings and thin rings of different thicknesses; Step 4: sintering: placing the pressed thick ring and thin ring into a vacuum furnace for sintering; Step five: molding. Brush glue on the steel wire rope, thread the sintered thick rings and thin rings into the rope in the required order, and use the corresponding mold for injection molding to form a beaded rope.

9. The small diameter diamond wire saw and the method for manufacturing the same according to claim 8, characterized in that: When preparing the FeCuCoNi alloy powder, the FeCoNi alloy powder is first prepared by an atomization method, and then Cu powder is added according to a proportion.

10. The small diameter diamond wire saw and the method for manufacturing the same according to claim 8, characterized in that: During the vacuum furnace sintering in step 4, the sintering temperature is 800-1000° C. and the holding time is 50-80 minutes.

Images