A high-sharpness high-cutting-edge rock plate cutter head and a preparation method thereof

Abstract

The application provides a high-sharpness and high-cutting-edge rock plate cutter head and a preparation method thereof, and relates to the technical field of diamond cutters. The method comprises the following steps: S1, mixing body powder according to a proportion in a three-dimensional mixer, adding silicon carbide to the formula of the body powder, and mixing for 50-120 minutes to obtain a body mixture; S2, uniformly distributing diamond particles in the body mixture by using a diamond adsorption device, and then performing pressing under a pressure of 500±50 kg / c㎡ to obtain a dense blank structure; S3, splicing the pressed blank, loading the blank into a multilayer graphite mold, sintering at high temperature, and maintaining the temperature for a preset time; S4, performing appearance treatment on the sintered cutter head, and welding the cutter head to a base; and S5, performing edge opening treatment on the cutter head by using a numerical control edge opening process, and then sequentially performing edge scraping, polishing and oil soaking treatment to optimize the surface quality and performance of the cutter head. The rock plate cutter head with high sharpness and high cutting edge is prepared by the method.

Description

Technical Field

[0001] This invention relates to the field of diamond cutting tool technology, and more specifically, to a high-sharpness, high-cutting-edge slab cutting tool and its preparation method. Background Technology

[0002] In the field of slab processing, diamond cutting tools are widely used as key cutting tools for efficient and precise material processing. However, existing diamond cutting tools have many technical defects in practical use, limiting further performance improvements. In conventional diamond cutting tools, the diamond particles are randomly distributed within the metal matrix. This distribution easily leads to segregation and aggregation, making it impossible for the cutting tool to maintain uniform and stable performance during cutting, thus affecting cutting sharpness and frequently causing edge chipping.

[0003] Furthermore, due to the uneven distribution of diamonds within the cutter head, only about 40% of the diamonds can effectively participate in the cutting operation, resulting in low cutting efficiency. As usage time increases, the cutting speed gradually slows down, and saw blade misalignment and edge chipping worsen, severely impacting processing quality. Simultaneously, areas with concentrated diamonds are easily polished due to excessive wear, while diamonds in sparse areas are prone to breakage or detachment. This uneven wear pattern significantly shortens the overall lifespan of the cutter head. Summary of the Invention

[0004] This invention discloses a method for preparing a high-sharpness, high-cutting-edge slab cutting tip, which has the effects of improving the uniformity of diamond distribution, improving cutting efficiency and cutting edge quality, and extending the service life of the cutting tip.

[0005] The present invention adopts the following solution:

[0006] A method for preparing a high-sharpness, high-cutting-edge slab cutter head, comprising:

[0007] S1: Place the carcass powder in a three-dimensional mixer according to the formula. The formula of the carcass powder includes 45%~50% copper powder, 10%~15% iron powder, 15%~20% zinc powder, 15%~20% cobalt powder, and 3%~5% silicon carbide by volume fraction. The mixing time is 50 minutes to 120 minutes to obtain the carcass mixture.

[0008] S2: Diamond particles are evenly distributed into the matrix mixture using a diamond adsorption device, and then pressed under a pressure of 500±50 kg / cm² to obtain a dense blank structure.

[0009] S3: After the pressed blanks are spliced ​​together, they are placed into a multi-layer graphite mold and sintered at a temperature of 760±50℃ for a preset time to achieve a firm bond between the matrix and the diamond particles.

[0010] S4: Perform surface treatment on the sintered cutting head and weld it to the substrate;

[0011] S5: The cutting head is sharpened using a CNC sharpening process, followed by scraping, polishing, and oil soaking to optimize the surface quality and performance of the cutting head.

[0012] Furthermore, in step S2, when laying diamond particles, 50 / 60 and 60 / 80 size diamond particles are mixed and matched in a 6:4 ratio in the middle of the matrix mixture to be embedded in the internal structure of the cutter body. Then, 80 / 100 size diamond particles are evenly arranged on the outside of the internal structure of the cutter body to form the external structure of the cutter body.

[0013] Furthermore, when arranging diamond particles layer by layer, when one-third of the first diamond is exposed, the second diamond is then inserted, thereby arranging the diamond particles in an array on both the internal and external structures of the cutting head.

[0014] Furthermore, the silicon carbide addition ratio is 4%.

[0015] Furthermore, in step S3, the heat preservation time is at least 1.5 minutes.

[0016] Furthermore, in step S4, the welding time is 4 seconds, and the weld strength is checked to be greater than 300 MPa.

[0017] The present invention also provides a slab cutter head, which is prepared by the aforementioned method for preparing a high-sharpness, high-cutting-edge slab cutter head.

[0018] Furthermore, the cutting head includes an external structure and an internal structure, and the diamond particles arranged on the external structure are larger than the diamond particles arranged on the internal structure.

[0019] Beneficial effects:

[0020] This solution addresses the problems of low cutting efficiency, poor edge quality, and short cutting head life caused by uneven diamond distribution in existing technologies by optimizing the matrix formula, diamond gradient distribution design, and precision sintering process. It has the advantages of improving diamond distribution uniformity, increasing cutting efficiency and edge quality, and extending cutting head life. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the diamond particle arrangement of a rock slab cutter head according to an embodiment of the present invention; Detailed Implementation

[0022] Example 1

[0023] This embodiment provides a method for preparing a high-sharpness, high-cutting-edge slab cutter head, including:

[0024] S1: Place the carcass powder in a three-dimensional mixer according to the formula. The formula of the carcass powder includes 45%~50% copper powder, 10%~15% iron powder, 15%~20% zinc powder, 15%~20% cobalt powder, and 3%~5% silicon carbide by volume fraction. The mixing time is 50 minutes to 120 minutes to obtain the carcass mixture.

[0025] S2: Diamond particles are evenly distributed into the matrix mixture using a diamond adsorption device, and then pressed under a pressure of 500±50 kg / cm² to obtain a dense blank structure.

[0026] S3: After the pressed blanks are spliced ​​together, they are placed into a multi-layer graphite mold and sintered at a temperature of 760±50℃ for a preset time to achieve a firm bond between the matrix and the diamond particles.

[0027] S4: Perform surface treatment on the sintered cutting head and weld it to the substrate;

[0028] S5: The cutting head is sharpened using a CNC sharpening process, followed by scraping, polishing, and oil soaking to optimize the surface quality and performance of the cutting head.

[0029] Among them, the three-dimensional mixer refers to a mixing device with multi-dimensional motion trajectory. Specifically, it can be a container with a planetary agitator, which achieves three-dimensional spatial diffusion of powder through a combination of rotation and revolution. The copper, iron, zinc, and cobalt powders in the matrix powder are elemental powders.

[0030] After precise proportioning, the matrix material is thoroughly mixed in a three-dimensional mixer, for example, by adjusting the mixing time to ensure uniform distribution of each component. The mixture and diamond particles are then evenly distributed by a specialized material distribution device, forming a preform structure with a predetermined density under a set pressure. During sintering, the metal powder undergoes diffusion and alloying reactions; for example, a metallurgical bond is formed between the copper-based matrix and the diamond surface. In one embodiment, the holding time can be set to 1.5 minutes, at which point the metal elements in the matrix powder have fully diffused, forming a continuous network structure that encapsulates the diamond particles, while the silicon carbide additive enhances the interfacial strength through solid solution strengthening.

[0031] This solution effectively improves the uniformity of diamond distribution by optimizing the matrix material system and mixing process. Increasing the pressing strength facilitates the formation of a denser matrix structure, while raising the temperature enhances the matrix's ability to encapsulate diamonds. This achieves an orderly arrangement of diamond particles within the matrix, increasing the proportion of diamonds effectively involved in cutting. The uniformly distributed matrix material effectively suppresses stress concentration during cutting, reducing the risk of saw blade sway. The optimized sintering process enhances the bonding strength between the matrix and diamonds, extending the saw head's lifespan. The dense preform structure improves the overall rigidity of the saw head, ensuring the stability of the cutting trajectory.

[0032] In a preferred embodiment, it is further proposed that when laying diamond particles, 50 / 60 and 60 / 80 diamond particles are mixed and matched in a 6:4 ratio in the middle of the matrix mixture to be embedded in the internal structure of the cutter body, and then 80 / 100 diamond particles are evenly arranged on the outside of the internal structure of the cutter body to form the external structure of the cutter body.

[0033] The mixing of 50 / 60 and 60 / 80 size diamond particles refers to combining two different diamond particle size ranges in a specific ratio. This can be achieved using mechanical vibration sieving to ensure uniform mixing, for example, by setting the vibration frequency to 20–30 Hz and the amplitude to 2–3 mm. The arrangement of 80 / 100 size diamond particles on the outer side of the blade body refers to covering the blade body surface with even finer diamond particles. This can be achieved using existing vacuum adsorption devices to achieve directional particle arrangement, for example, by adjusting the adsorption pressure to 0.5–0.8 MPa and the feeding speed to 10 mm / s to achieve a tight particle layer.

[0034] When embedding mixed-size diamonds in the middle layer of the carcass mixture, the vibration screening parameters are controlled to create an alternating support structure between 50 / 60 and 60 / 80 particles. The 50 / 60 particles provide basic support strength, while the 60 / 80 particles fill the gaps to increase structural density. When 80 / 100 size diamonds are arranged on the outer side of the cutter body, a gradient pressure pressing process is used to ensure the fine particles are tightly adhered to the middle layer, forming a dense and uniform cutting surface. Through layer-by-layer arrangement, the coarse particles in the middle layer and the fine particles on the outer layer form a gradient transition structure in mechanical properties. The combination of different particle sizes improves the continuity of the diamonds; coarse-grained diamonds improve machinability, while fine-grained diamonds provide better edge quality, resulting in good cutting speed and edge performance.

[0035] Compared to using a single-size, randomly distributed particle, which easily leads to particle detachment in stress concentration areas during cutting, this solution employs a layered arrangement of particles of different sizes. The middle layer of coarse particles bears the main cutting load, while the outer layer of fine particles maintains the smoothness of the cutting surface, thus avoiding localized stress imbalance caused by particle aggregation. This solves the problems of low cutting efficiency and edge chipping defects caused by uneven diamond particle distribution. The combination of coarse particles in the middle layer enhances the impact resistance of the tool body's internal structure, while the outer layer of fine particles effectively reduces the roughness of the cutting surface. The synergistic effect of both ensures that the tool maintains a stable cutting depth and trajectory accuracy during cutting.

[0036] In this embodiment, when arranging diamond particles layer by layer, the second diamond is connected when one-third of the first diamond is exposed, thus creating an array arrangement of diamond particles on both the internal and external structures of the cutting head. Layer-by-layer arrangement of diamond particles refers to arranging diamond particles of different sizes in different areas of the cutting head through a layered approach. Specifically, a mechanical positioning device can be used to achieve layered positioning, and local aggregation can be avoided by controlling the particle spacing. The "one-third exposed" refers to the exposure height of the diamond particles in the matrix mixture, which can be achieved by adjusting the pressing depth, ensuring the particles maintain an effective cutting surface while avoiding excessive protrusion. Connecting the second diamond means forming a continuous cutting surface between adjacent particles, which can be achieved using a staggered arrangement method, where the stability of the subsequent particle is maintained by the supporting effect of the preceding particle. The array arrangement refers to the diamond particles forming a regular geometric arrangement at a preset spacing.

[0037] During the cutting head pressing process, when the first diamond particle is pressed into the matrix mixture to a depth of two-thirds, the adjacent second particle is positioned at its lateral interval. By continuously repeating this operation, the diamond particles form a staggered structure inside the cutting head, with each layer of particles maintaining a consistent exposure height. In the external structure of the cutting head, the particle spacing is further reduced, forming a denser cutting unit. This arrangement allows the diamond particles to participate in the cutting operation sequentially, avoiding stress concentration caused by multiple particles simultaneously contacting the machined surface. By controlling the particle exposure height and spacing, the diamond particles form an orderly arrangement within the matrix, effectively eliminating particle accumulation. During the cutting operation, each diamond particle can participate in the cutting in a predetermined order, avoiding fluctuations in cutting resistance caused by uneven particle distribution. This achieves an orderly distribution of diamond particles in the cutting head, ensuring that the cutting force is evenly transmitted to each particle, reducing particle shedding due to local overload. The supporting effect of adjacent particles enhances the stability of the overall structure, maintaining the integrity of the cutting head geometry during high-speed cutting. The regularly arranged particles form a continuous cutting trajectory, which effectively reduces the roughness of the cut surface and suppresses the occurrence of edge chipping defects.

[0038] This application further proposes a method for preparing a high-sharpness, high-cutting-edge slab cutter head, including adding silicon carbide to the matrix powder at a ratio of 4%. The silicon carbide addition ratio refers to the volume fraction of silicon carbide in the matrix powder, which can be achieved by adjusting the amount of silicon carbide added during the mixing process. Controlling this ratio at 4% effectively enhances the matrix hardness while avoiding the problem of reduced bonding force between the matrix and diamond particles during sintering due to excessive addition. As a hard phase additive, silicon carbide forms a dispersed strengthening structure with the metal matrix during sintering, thereby improving the overall wear resistance of the cutter head.

[0039] In the matrix preparation stage, silicon carbide, copper powder, iron powder, zinc powder, and cobalt powder are added to a three-dimensional mixer in a specific volume ratio. When the silicon carbide content reaches 4%, its distribution density in the matrix forms a continuous reinforcing network without excessively hindering the diffusion and bonding of the metal powders. During the subsequent sintering process, the silicon carbide particles undergo an interfacial reaction with the metal matrix, forming a stable composite structure. This structure effectively suppresses plastic deformation of the matrix during cutting and maintains the support stability of the diamond particles.

[0040] This solution, by limiting the silicon carbide addition to 4%, ensures both the strength of the matrix in holding the diamond and the formation of a high-hardness composite matrix through the synergistic effect of silicon carbide and metal. This solves the problem of reduced edge quality caused by matrix deformation during cutting. It achieves a balanced optimization of the hardness and toughness of the cutting head matrix, effectively maintaining the stable arrangement of diamond particles during cutting and preventing particle detachment due to matrix softening. Simultaneously, the strengthening effect of silicon carbide allows the cutting head to maintain structural integrity under high-temperature cutting conditions, avoiding cutting trajectory deviation caused by thermal deformation.

[0041] In step S4, the welding time is set to 4 seconds, and the weld strength is checked to be greater than 300 MPa. The welding time refers to the duration for which the cutting head and the substrate are joined through the welding process. This time can be controlled using high-frequency induction welding equipment, and precise control of the heating time prevents microstructural changes in the substrate material due to overheating. The weld strength refers to the maximum load that the weld interface can withstand per unit area. This strength can be tested using a universal testing machine to ensure a strong bond between the cutting head and the substrate.

[0042] Specifically, during the welding process, the welding head and the substrate are positioned in a fixture, and then the welding area is locally heated using a high-frequency induction coil. The welding time is set to 4 seconds, during which time the substrate material and the substrate surface reach a molten state and form a metallurgical bond. After welding, the weld interface is sampled and inspected, and a tensile test is conducted to verify whether its strength reaches 300 MPa or higher. Products that do not meet the standard are rejected.

[0043] This solution optimizes the relationship between welding time and strength indicators, reducing the heat-affected zone while ensuring joint strength, thus preventing the cutter head performance from deteriorating due to heat damage. It effectively solves the problem of cutter head detachment caused by insufficient welding strength, ensuring a stable connection between the cutter head and the substrate under high-speed cutting conditions, thereby extending the overall tool life and improving the safety of the cutting process.

[0044] Example 2

[0045] This embodiment provides a method for preparing a high-sharpness, high-cutting-edge slab cutter head, including:

[0046] S1: The carcass powder is mixed in a three-dimensional mixer according to the following formula: 48% copper powder, 12% iron powder, 17% zinc powder, 19% cobalt powder, and 4% silicon carbide. These powders are mixed in the three-dimensional mixer for 90 minutes to obtain the carcass mixture.

[0047] S2: Diamond particles are evenly distributed into the matrix mixture using a diamond adsorption device. In the middle part of the matrix mixture, 50 / 60 and 60 / 80 size diamond particles are mixed in a 6:4 ratio to form the internal structure of the blade. Then, 80 / 100 size diamond particles are evenly distributed on the outer side to form the external structure of the blade. When arranging the diamond particles layer by layer, when one-third of the first diamond is exposed, the second diamond is connected to form an array arrangement.

[0048] S3: Pressing is performed under a pressure of 500 kg / cm² to obtain a dense green body structure. The pressed green bodies are then assembled and placed into a multi-layer graphite mold, sintered at 760℃ and held for 1.5 minutes to achieve a strong bond between the matrix and diamond particles.

[0049] S4: Perform surface treatment on the sintered cutter head and weld it to the substrate. The welding time is 4 seconds, and the welding strength is greater than 300MPa.

[0050] S5: The cutting head is sharpened using a CNC sharpening process, followed by scraping, polishing, and oil soaking to optimize the surface quality and performance of the cutting head.

[0051] The slab cutter head prepared by this method has a uniform distribution of diamond particles, a reasonable internal and external structure, and can maintain stable cutting performance, improve cutting efficiency, and extend service life.

[0052] To verify the effect of silicon carbide addition on the performance of the cutting head, a set of experiments was conducted. Specifically, based on the formulation of the matrix mixture in this embodiment, the contents of copper powder, iron powder, zinc powder, and cobalt powder remained approximately unchanged, and other steps and parameters were the same. The difference was that the silicon carbide dosage was 0%, 3%, 4%, and 5%, respectively. When adjusting the silicon carbide content, the contents of copper powder, iron powder, zinc powder, and cobalt powder could be adjusted proportionally to ensure that the total volume fraction was the same in each experimental group. Experiments were conducted on the cutting current and power of the prepared cutting head. The comparison of the obtained cutting current is shown in Table 1, and the comparison of the obtained power is shown in Table 2.

[0053] Table 1

[0054]

[0055] Table 2

[0056]

[0057] Note:

[0058] 1. Comparison benchmark: Cutting head without silicon carbide (100%).

[0059] 2. Experimental conditions: Cutting speed 2mm / s, rock slab thickness 10mm (material: granite).

[0060] The experimental data above shows that adding silicon carbide results in lower cutting current and power compared to not adding it, with the lowest cutting current and power achieved when the silicon carbide content is 4%. Under the same working conditions and cutting efficiency, lower power consumes less electricity, and lower cutting current results in better sharpness. Therefore, the slab cutter head exhibits superior performance when the silicon carbide content is 4%.

[0061] Example 3

[0062] Combination Figure 1 This embodiment provides a slab cutting head, which is prepared by the aforementioned method for preparing a high-sharpness, high-cutting-edge slab cutting head. The cutting head includes an external cutting head structure and an internal cutting head structure, wherein the diamond particles arranged on the external cutting head structure have a larger particle size than the diamond particles arranged on the internal cutting head structure.

[0063] The diamond particles are evenly and orderly distributed within the cutting head. The outer layer of fine particles continuously participates in the cutting operation, while the inner coarse particles provide structural support. The matrix bond maintains a stable shape at high temperatures. This structure effectively avoids problems such as wobble, chipping, and abnormal wear caused by uneven particle distribution during cutting, allowing the cutting head to maintain high sharpness while extending its service life.

[0064] The external structure of the cutter body refers to the surface layer area where the cutter head directly contacts the object being cut. This can be achieved using a composite layer formed by pressing a mixture of diamond particles and matrix material. This structure bears the primary cutting function. The internal structure refers to the support layer area beneath the external structure within the cutter head. This can be formed by layering and pressing a mixture of diamond particles of different sizes with a matrix material. This structure enhances the overall strength of the cutter head. The difference in diamond particle size refers to the use of finer particles in the external structure to ensure better edge quality, and coarser particles in the internal structure to improve machinability. Through particle size grading and structural layering, the diamond particles form an orderly gradient distribution within the cutter head, avoiding stress concentration caused by particle aggregation and insufficient support due to missing particles, thereby improving cutting stability.

[0065] In the above embodiments, through innovative formulations and processes, the concentration and distribution of diamond are precisely controlled, ensuring their uniform and orderly arrangement within the cutting head. This significantly improves the effective utilization rate of diamond, reduces cutting resistance, and increases drainage, resulting in a smooth and unobstructed cutting process. By optimizing the matrix bond formula and adding high-performance silicon carbide additives, the hardness and thermal stability of the cutting head are significantly enhanced, suppressing wear and deformation during cutting, ensuring precise cutting trajectories and smooth, flat edges. Furthermore, the scientifically designed cutting head structure combined with advanced manufacturing processes improves overall strength and impact resistance, maintaining stable cutting performance under complex working conditions. Cutting efficiency is increased by more than 40% compared to traditional cutting heads.

[0066] The cutting head prepared using this method exhibits excellent stability and wear resistance. By optimizing the matrix bond formula and adding high-performance silicon carbide additives, the hardness and thermal stability of the cutting head are significantly enhanced. During cutting, it effectively inhibits wear and deformation, ensuring precise cutting trajectory, smooth and even edges, and eliminating defects such as chipping and burrs, meeting the stringent requirements of high-end slab processing. This method solves the problem of trajectory deviation caused by matrix softening during diamond cutting, avoids edge chipping defects caused by stress concentration, and improves the surface roughness. Simultaneously, by optimizing the diamond distribution pattern, the load impact on individual diamonds during cutting is reduced, extending the cutting head's service life. Furthermore, the strengthened matrix bond effectively inhibits abnormal diamond shedding, maintaining the stability of the cutting process.

[0067] It should be understood that the above are merely preferred embodiments of the present invention, and the scope of protection of the present invention is not limited to the above embodiments. All technical solutions that fall within the scope of the present invention are within the scope of protection of the present invention.

[0068] The accompanying drawings used in the above description of the embodiments only illustrate certain embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

Claims

1. A method for preparing a high-sharpness, high-cutting-edge slab cutter head, characterized in that, include: S1: Place the carcass powder in a three-dimensional mixer according to the formula. The formula of the carcass powder includes 45%~50% copper powder, 10%~15% iron powder, 15%~20% zinc powder, 15%~20% cobalt powder, and 4% silicon carbide by volume fraction. The mixing time is 50 minutes to 120 minutes to obtain the carcass mixture. S2: Diamond particles are evenly distributed into the matrix mixture using a diamond adsorption device, and then pressed under a pressure of 500±50 kg / cm² to obtain a dense blank structure. S3: After the pressed blanks are spliced ​​together, they are placed into a multi-layer graphite mold and sintered at a temperature of 760±50℃ for a preset time to achieve a firm bond between the matrix and the diamond particles. S4: Perform surface treatment on the sintered cutting head and weld it to the substrate; S5: The cutting head is sharpened using a CNC sharpening process, followed by scraping, polishing, and oil soaking to optimize the surface quality and performance of the cutting head. In step S2, when laying diamond particles, 50 / 60 and 60 / 80 diamond particles are mixed in a 6:4 ratio in the middle of the matrix mixture to be embedded in the internal structure of the cutting head. Then, 80 / 100 diamond particles are evenly distributed on the outside of the internal structure of the cutting head to form the external structure of the cutting head.

2. The method for preparing a high-sharpness, high-cutting-edge slab cutter head according to claim 1, characterized in that, When arranging diamond particles layer by layer, the second diamond is connected when one-third of the first diamond is exposed, so that the diamond particles are arranged in an array on the internal and external structures of the cutting head.

3. The method for preparing a high-sharpness, high-cutting-edge slab cutter head according to claim 1, characterized in that, In step S3, the heat preservation time is at least 1.5 minutes.

4. The method for preparing a high-sharpness, high-cutting-edge slab cutter head according to claim 1, characterized in that, In step S4, the welding time is 4 seconds, and the weld strength is checked to be greater than 300 MPa.

5. A slab cutting head, characterized in that, It is prepared by the method for preparing the high-sharpness, high-cutting-edge slab cutter head according to any one of claims 1-4.

6. The slab cutter head according to claim 5, characterized in that, The cutting head includes an external structure and an internal structure, and the diamond particles arranged on the external structure are larger than the diamond particles arranged on the internal structure.

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