Design method for orderly-arranged tool bits of large disk saw blade

Abstract

The invention provides a design method for orderly-arranged tool bits of a large-disk saw blade, which comprises the following steps of: granulating metal matrix powder based on a needle tube type vacuum adsorption method, and controlling the granularity and the morphology of the metal matrix powder; designing the overall configuration of the tool bit; at least two sets of screen plates with different hole site patterns and matched parameters are designed for alternately distributing sand, and interlayer diamond dislocation is achieved; the tool bit is designed to be of a multi-layer structure in the top edge direction, so that the arrangement density of edge layer diamonds is higher than that of the middle, and the interlayer spacing of the middle is widened to form a chip removal water tank. According to the method, ordered and differentiated arrangement of the diamonds in the large-size tool bit is achieved, the cutting sharpness is comprehensively improved, the service life is comprehensively prolonged, and the chip removal performance is comprehensively improved.

Description

Technical Field

[0001] This invention relates to the field of diamond tool manufacturing, and more particularly to a design method for an orderly arrangement of cutter heads on a large circular saw blade. Background Technology

[0002] Diamond tools are widely used in cutting materials such as stone. The uniformity of diamond distribution within the metal matrix is ​​a key factor affecting tool performance. Currently, conventional diamond tools are prone to diamond segregation and aggregation, leading to low diamond utilization. This results in a trade-off between tool sharpness and lifespan, making it difficult to maintain consistent product quality. Therefore, achieving an orderly arrangement of the cutting head to improve the cutting performance and quality of diamond saw blades has become a crucial issue that urgently needs to be addressed in the industry.

[0003] Currently, methods for achieving ordered diamond cutting head arrangement mainly include diamond pre-coating, dispensing, and needle-type vacuum adsorption. However, existing ordered cutting head designs primarily focus on small- to medium-diameter saw blades. For large circular saw blades with diameters of 3.5 meters and above, the complex forces, high chip removal requirements, and stringent demands on edge quality and blade life during cutting make directly applying the ordered arrangement technology of small- to medium-sized cutting heads unsuitable. In particular, during cutting, the edges and center of large circular saw blades perform different functions; the edges directly determine the quality of the cut surface, while the center affects chip removal efficiency and continuous cutting capability. Existing technologies lack specific solutions for differentiated diamond arrangement and layer structure design for different functional areas of the cutting head, making it difficult to extend the overall lifespan of large saw blades while maintaining sharpness, and also failing to effectively optimize chip removal performance.

[0004] Therefore, there is a gap in the existing technology for adapting ordered arrangement technology to large circular saw blades. In particular, there is a lack of a systematic method that can specifically design the diamond arrangement density and interlayer structure according to the different functional requirements of the edge and center of the blade, so as to comprehensively improve the cutting quality, chip removal capacity and service life of large circular saws. Summary of the Invention

[0005] In view of this, the purpose of this invention is to provide a design method for orderly arrangement of diamond cutting heads in a large circular saw blade, which realizes the orderly arrangement and differentiated distribution of diamonds in the cutting head of the large circular saw blade, thereby improving the cutting sharpness, service life and chip removal capacity of the cutting head, and optimizing the production process.

[0006] The technical solution adopted by this invention to solve its technical problem is: A design method for orderly arranging the cutter heads of a large circular saw blade is provided, including the following steps: S1. Based on the needle-type vacuum adsorption method, the metal matrix powder is granulated so that the particle size of the granulated powder is consistent with the particle size of the selected diamond, and the morphology of the granulated powder is a near-circular shape with irregular edges and corners. S2. Design the overall shape and size of the cutter head according to the size of the large circular saw blade; S3. Design at least two sets of orderly arranged mesh plates, each set of mesh plates having a hole diameter larger than the diameter of the selected diamond, and the diameter of the needle tube used to adsorb the diamond being smaller than the diameter of the selected diamond; the hole patterns of the at least two sets of mesh plates are different, and they are used alternately during the cutting head forming process so that the diamond positions between different layers are staggered. S4. The cutting head is designed as a multi-layer structure along the top cutting edge direction, wherein the diamond arrangement density near the edge layer of the cutting head is greater than that in the middle layer, and the thickness of the outermost layer is not less than the diameter of the selected diamond; the spacing between the middle layers is widened to form a recessed water groove that facilitates chip removal during the operation of the cutting head.

[0007] Preferably, the powder granulation in step S1 specifically includes: adding a granulating agent solution to the metal matrix powder and stirring evenly; feeding the mixed powder into a feeder for high-speed feeding until water mist separation is observed after opening the feeder cover; screening the powder using a sieve of appropriate mesh size according to the selected diamond particle size; and adding the screened powder into a granulation device for extrusion molding to ensure that the powder particle size is consistent with the diamond particle size.

[0008] Preferably, the type of granulating agent solution is determined according to the composition and flowability requirements of the metal matrix powder to ensure that the granulated powder meets the sand distribution requirements of the needle-type vacuum adsorption method.

[0009] Preferably, the large circular saw blade in step S2 has a specification of 3.5m, and the corresponding cutter head size is 24mm×13mm×30mm. The cutter head has an overall rectangular structure to accommodate the installation and cutting requirements of the 3.5m large circular saw blade.

[0010] Preferably, the stencil in step S3 is a 24mm × 30mm rectangular plate adapted to the size of the rectangular cutter head, and the diameter of the plate holes in the stencil is... 0.55-0.65mm.

[0011] Preferably, in step S3, there are two sets of stencils, and the hole patterns of the two sets of stencils are staggered. When used alternately, the diamonds between adjacent layers can be completely staggered.

[0012] Preferably, the two sets of stencils are A225 stencils and B207 stencils, respectively. The hole spacing of the A225 stencil is 2.25-2.35 mm, and the hole spacing of the B207 stencil is 2.4-2.5 mm. The two work together to achieve precise misalignment of the diamonds between layers.

[0013] Preferably, the aperture, longitudinal distance between apertures, and transverse column width of the mesh plate in step S3 are designed in a coordinated manner, and the combination of these parameters enables the cutter head to continuously be in an effective cycle of diamond abrasive grain breakage, shedding, and new abrasive grain emergence during cutting.

[0014] Preferably, the diamond arrangement density near the edge layer of the cutting head in step S4 satisfies the following: the distance between adjacent diamonds is less than 1.5 times the diameter of the selected diamond, the distance between each layer in the middle is 2-3 times the center-to-center distance between adjacent diamonds in the edge layer, and the depth of the recessed water groove is not less than 0.8 mm.

[0015] Preferably, the process further includes step S5: according to the design parameters of steps S1-S4, the granulated metal matrix powder and the diamonds arranged in an orderly manner on the mesh plate are loaded into the mold together, and the cold pressing process is used to form the cutter head blank in one step. No iron sheet needs to be added during the forming process, and the separate sheet arrangement process is eliminated.

[0016] The beneficial effects of this invention are: This invention provides a design method for the orderly arrangement of diamond cutting heads in large circular saw blades. By controlling the morphology and particle size of the powder, the method ensures stable diamond arrangement. Multi-layered staggered mesh plates are used to achieve orderly and precise diamond arrangement within the cutting head. Differentiated layer structure designs are implemented based on the different functional requirements of the edge and center of the cutting head, thereby comprehensively improving the cutting sharpness, service life, and chip removal performance of the cutting head. Simultaneously, the one-time cold-pressed blank molding design eliminates the cumbersome blade arrangement process and additional iron sheet addition steps in traditional processes, simplifying the production process and reducing manual labor intensity. Furthermore, the orderly arrangement technology has been successfully applied to 3.5m large circular saw cutting heads, filling a technological gap in the industry. It precisely adapts to the standardized, high-volume demands of low- to mid-range stone processing, helping large circular saws withstand the market impact of wire saw equipment, significantly enhancing their core competitiveness in related processing fields, and providing a practical and feasible solution for industry process upgrades. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the granulation extrusion molding apparatus of the present invention.

[0018] Figure 2 This is a schematic diagram of the morphology of the granulated powder under a high-magnification microscope according to the present invention.

[0019] Figure 3 This is a schematic diagram of the cutter head dimensions of the present invention.

[0020] Figure 4 This is a schematic diagram of the rectangular A225 mesh plate of the present invention.

[0021] Figure 5 This is a schematic diagram of the rectangular B207 mesh plate of the present invention.

[0022] Figure 6 This is a diagram showing the combined effect of the two mesh panels of the present invention.

[0023] Figure 7 This is a schematic cross-sectional view of the orderly arranged cutter head in the direction of the cutting edge according to the present invention.

[0024] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] like Figures 1-7 As shown, this embodiment provides a method for designing an orderly arrangement of diamond cutting heads for a 3.5-meter diameter large circular saw blade. This method aims to solve the problems of uneven diamond distribution, low utilization rate, and difficulty in balancing cutting performance and lifespan in large saw blade cutting heads. The core of this method lies in achieving an orderly, precise, and differentiated arrangement of diamond particles along functional areas inside the cutting head through systematic powder pretreatment, structural design, and arrangement process control.

[0027] S1. Granulation treatment of metal matrix powder (to ensure the stability of diamond arrangement) The core of this step is to optimize the flowability and formability of the powder through granulation, providing a supporting foundation for the orderly arrangement of diamonds. The specific operation is as follows: First, based on the selected needle-type vacuum adsorption sand distribution process, the metal matrix powder is pretreated. Because this process has strict requirements on the flowability and particle size of the powder, it is necessary to calculate and add an appropriate type and proportion of granulating agent solution (such as polyvinyl alcohol solution) according to the specific composition of the matrix powder (such as iron powder, copper powder, cobalt powder, etc.). The powder and granulating agent solution are then placed in a mixer and thoroughly stirred to ensure complete wetting.

[0028] Subsequently, the uniformly mixed wet material is placed into a high-speed mixer for strong dispersion and preliminary granulation. The mixing process needs to be continued until, when the mixer cover is opened, a clear water mist separation phenomenon can be observed in the powder. At this point, it indicates that the powder has reached the appropriate moisture content and has a basis for agglomeration, and the mixing can be stopped.

[0029] Next, based on the particle size of the diamond particles planned for use in subsequent steps (e.g., 40 / 50 mesh), select a sieve with an appropriate mesh size (e.g., 40 mesh) and install it on the granulation equipment. The powdered material is then fed into the granulation equipment, where it is mechanically extruded through the sieve to form uniformly sized particles. Figure 2 As shown, under a high-powered microscope, the morphology of the extruded powder particles should be nearly circular with irregular edges and corners. This morphology, coupled with its particle size matching that of the diamond particles, allows the powder to effectively encapsulate and fix the diamonds during the subsequent abrasive application process, preventing positional shifts in the diamonds during transfer or pressing and ensuring precise, orderly arrangement.

[0030] S2. Cutter head size design (suitable for 3.5m large circular saw blade applications) For a large circular saw blade with a diameter of 3.5 meters, to adapt to its mounting base and meet the mechanical requirements of large-scale, standardized stone cutting, the specific dimensions of the cutter head in this embodiment are: length 24 mm, width 13 mm, and height 30 mm, with an overall regular rectangular block structure, such as... Figure 3 As shown. This size design ensures that the blade head has sufficient contact area and cutting volume, while facilitating arrangement and welding around the periphery of large saw blades.

[0031] S3. Design and use of ordered mesh plates (to achieve precise staggered arrangement of diamonds) The stencil is the core component for achieving multi-layered staggered arrangement of diamonds. This step ensures arrangement accuracy through parameter coordination design and alternating use, as detailed below: I. Basic parameter design of the stencil: The diameter of the holes in the array on the stencil must be greater than the maximum diameter of a single selected diamond to ensure that the diamond can fall in or pass through smoothly; while the diameter of the end of the needle (or nozzle) used to generate negative pressure to adsorb the diamond should be slightly smaller than the diameter of the diamond to ensure that only a single diamond can be adsorbed and fixed at a time, avoiding multiple diamonds from sticking together.

[0032] II. To achieve staggered arrangement, in order to ensure that the diamonds deposited in different layers (perpendicular to the cutting direction) are completely staggered in spatial position and to avoid stress concentration zones formed by vertical alignment, it is necessary to design and use two or more sets of mesh plates with different hole arrangement patterns, and use them alternately during the cutting head forming process.

[0033] In this embodiment, two specific sets of mesh panels are used: A225 mesh panel and B207 mesh panel. The mesh panels are made of 304 stainless steel, 2mm thick, and possess sufficient rigidity and wear resistance, and are reusable. Figure 4 and Figure 5 As shown, both sets of stencils are rectangular plates that perfectly match the dimensions of the cutter head's top cutting edge (24mm × 30mm). The hole spacing of the A225 stencil is designed to be 2.25-2.35mm (e.g., 2.3mm), and the hole spacing of the B207 stencil is designed to be 2.4-2.5mm (e.g., 2.45mm). The diameter of the holes in the stencils is uniformly φ0.55-0.65mm (e.g., φ0.6mm). By alternating between plates A and B for abrasive application, a pattern can be formed inside the cutter head as shown in the image. Figure 6 The merging effect shown is that the projection positions of the diamonds in the upper and lower layers are completely staggered and do not overlap. In addition, the parameters such as the aperture of the mesh, the longitudinal distance between the holes, and the transverse column width are synergistically optimized. Their combination ensures that when the final cutter head is cutting stone, the diamond abrasive grains on the working surface are continuously in a highly efficient and stable cycle of "grinding and breaking - old grain falling off - new grain emerging", thus maintaining the cutting sharpness.

[0034] S4. Multi-layer differentiated structure forming of the cutter head (adapting to the functional requirements of the edge and center). Considering the different functional requirements of different areas of the blade head during cutting with a large circular saw blade, this embodiment features a differentiated design for the internal layer structure of the blade head; for example... Figure 7 As shown, the cutter head is designed as a multi-layered composite structure arranged along its top edge (cutting direction), rather than a uniform single layer.

[0035] High-density edge layer: To obtain a smooth, straight cutting surface and improve edge quality, the outermost diamond layers closest to both sides of the cutting head need to be arranged as densely as possible. In this design, the diamond arrangement density near the edge layer satisfies the following condition: the center-to-center distance between adjacent diamond particles is less than 1.5 times the nominal diameter of the selected diamond. Simultaneously, the thickness of the outermost layer (i.e., the thickness of this densely arranged layer) must not be less than the diameter of the selected diamond to ensure the strength and durability of the cutting edge.

[0036] Wide-spacing water channel area in the middle: In the central area of ​​the cutting edge, the vertical spacing between each diamond layer is intentionally increased. Specifically, the spacing between two adjacent layers in the middle is designed to be 2 to 3 times the center-to-center spacing of the diamond layers mentioned above. During the cutting process, the widened layer spacing naturally forms a series of regular concave structures extending along the cutting direction, namely "chip removal water channels". The depth of these channels is not less than 0.8 mm. Their beneficial effect is to significantly improve the chip holding and chip removal capacity of the cutting edge, promptly removing stone powder and debris generated during cutting, thereby effectively reducing cutting resistance and cutting edge temperature, preventing chipping, and improving cutting efficiency and cutting edge life.

[0037] After completing the design and parameter preparation of steps S1 to S4 above, the physical manufacturing stage of the cutter head is entered (step S5). According to the designed parameters, the granulated metal matrix powder is used as the matrix, and diamond particles that are arranged in an orderly and staggered manner by alternating vacuum adsorption through A225 and B207 mesh plates are precisely loaded into the molding mold. Subsequently, the cold pressing process is used to press and form the cutter head cold pressing blank in one go.

[0038] It should be noted that, thanks to the uniform stress distribution and high strength resulting from the orderly arrangement of the structure, the cutter blank formed using this method has a robust structure, eliminating the need for additional reinforcing structural components such as iron sheets during the pressing process, as is required in traditional large cutter manufacturing processes. This not only simplifies the mold structure and mold assembly operation but also directly eliminates the tedious "sheet arrangement" process (i.e., manually arranging iron sheets) in traditional processes, thereby significantly improving mold assembly efficiency, reducing labor costs, and making the production process more standardized and efficient.

[0039] Finally, it should be noted that the above description is merely a preferred embodiment of the present invention and is only used to illustrate the technical solution of the present invention, and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention are included within the scope of protection of the present invention.

Claims

1. A design method for orderly arranging the cutter heads of a large circular saw blade, characterized in that, Includes the following steps: S1. Based on the needle-type vacuum adsorption method, the metal matrix powder is granulated so that the particle size of the granulated powder is consistent with the particle size of the selected diamond, and the morphology of the granulated powder is a near-circular shape with irregular edges and corners. S2. Design the overall shape and size of the cutter head according to the size of the large circular saw blade; S3. Design at least two sets of orderly arranged mesh plates, each set of mesh plates having a hole diameter larger than the diameter of the selected diamond, and the diameter of the needle tube used to adsorb the diamond being smaller than the diameter of the selected diamond; the hole patterns of the at least two sets of mesh plates are different, and they are used alternately during the cutting head forming process so that the diamond positions between different layers are staggered. S4. The cutting head is designed as a multi-layer structure along the top cutting edge direction, wherein the diamond arrangement density near the edge layer of the cutting head is greater than that in the middle layer, and the thickness of the outermost layer is not less than the diameter of the selected diamond; the spacing between the middle layers is widened to form a recessed water groove that facilitates chip removal during the operation of the cutting head.

2. The design method for orderly arrangement of cutter heads in a large circular saw blade as described in claim 1, characterized in that: The powder granulation in step S1 specifically includes: adding a granulating agent solution to the metal matrix powder and stirring it evenly; feeding the mixed powder into a feeder for high-speed feeding until water mist separation is observed after opening the feeder cover; screening the powder with a sieve of appropriate mesh size according to the selected diamond particle size; adding the screened powder into a granulation device and extruding it to make the powder particle size consistent with the diamond particle size.

3. The design method for orderly arrangement of cutter heads in a large circular saw blade as described in claim 2, characterized in that: The type of granulating agent solution is determined according to the composition and flowability requirements of the metal matrix powder to ensure that the granulated powder meets the sand distribution requirements of the needle-type vacuum adsorption method.

4. The design method for orderly arrangement of cutter heads in a large circular saw blade as described in claim 1, characterized in that: The large circular saw blade in step S2 has a specification of 3.5m and a corresponding cutter head size of 24mm×13mm×30mm. The cutter head has an overall rectangular structure to accommodate the installation and cutting requirements of the 3.5m large circular saw blade.

5. The design method for orderly arrangement of cutter heads in a large circular saw blade as described in claim 4, characterized in that: The stencil in step S3 is a 24mm × 30mm rectangular plate adapted to the size of the rectangular cutter head, and the diameter of the plate holes in the stencil is... 0.55-0.65mm.

6. The design method for orderly arrangement of cutter heads in a large circular saw blade as described in claim 1, characterized in that: In step S3, there are two sets of stencils. The hole patterns of the two sets of stencils are staggered. When used alternately, the diamonds between adjacent layers can be completely staggered.

7. The design method for orderly arrangement of cutter heads in a large circular saw blade as described in claim 6, characterized in that: The two sets of stencils are A225 stencil and B207 stencil. The hole spacing of the A225 stencil is 2.25-2.35mm, and the hole spacing of the B207 stencil is 2.4-2.5mm. The two work together to achieve precise misalignment of the diamonds between layers.

8. The design method for an orderly arrangement of cutter heads in a large circular saw blade as described in claim 6, characterized in that: The aperture, longitudinal distance between holes, and transverse column width of the mesh plate mentioned in step S3 are designed in a coordinated manner. The combination of these parameters enables the cutter head to continuously be in an effective cycle of diamond abrasive grain breaking, shedding, and new abrasive grain emerging during the cutting process.

9. The design method for orderly arrangement of cutter heads in a large circular saw blade as described in claim 1, characterized in that: In step S4, the diamond arrangement density near the edge layer of the cutting head satisfies the following conditions: the distance between adjacent diamonds is less than 1.5 times the diameter of the selected diamond; the distance between each layer in the middle is 2-3 times the center-to-center distance between adjacent diamonds in the edge layer; and the depth of the recessed water groove is not less than 0.8 mm.

10. A design method for orderly arranged cutter heads of a large circular saw blade as described in any one of claims 1-9, characterized in that: It also includes step S5: according to the design parameters of steps S1-S4, the granulated metal matrix powder and the diamonds arranged in an orderly manner on the mesh plate are loaded into the mold together, and the cold pressing process is used to form the cutter head blank in one step. No iron sheet is needed during the forming process, and the separate sheet arrangement process is eliminated.

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