Wire saw structure

Abstract

The utility model discloses a rope saw structure which comprises a core wire, a blade material and a consolidation object, the blade material wraps the periphery of the core wire through the consolidation object to form a plurality of blade sections, the blade sections are discontinuously distributed in the length direction (namely the axial direction) of the core wire, and a groove is formed between every two adjacent blade sections. According to the scheme, the multiple blade sections composed of the consolidated materials with the blade materials are distributed on the core wire, the blade sections are discontinuously distributed, that is, a gap or a groove is formed between every two adjacent blade sections, in this way, during cutting machining, waste chips can be discharged from the grooves, and the grooves can also contain and drive cooling liquid to be better cooled during machining; in addition, the blade sections distributed at intervals are similar to sawteeth in structure, cutting steps are formed, and the cutting efficiency can be improved due to the sawteeth principle during cutting machining. According to the wire saw structure, under the combined action, the overall cutting machining efficiency and the cutting effect are improved. The device is simple in structure, easy to operate and capable of being universally applied to wire saw machining.

Description

Technical Field

[0001] This utility model belongs to the field of wire saw technology, and in particular relates to a wire saw structure. Background Technology

[0002] A wire saw, also known as a wire saw when the core wire is a single wire, is a multi-functional cutting tool with a wide range of designs and applications, suitable for cutting materials in various fields. One existing method for manufacturing wire saws involves attaching a blade-like material to the outer surface of the core wire, resulting in high efficiency, high cleanliness, and a long service life during cutting, as described in publication number CN102172999B.

[0003] like Figure 1 As shown, in existing wire saws, the bonded material and cutting edge are laid continuously on the core wire, making chip removal difficult during wire saw cutting and hindering the flow of coolant, thus affecting the cutting effect and efficiency. Furthermore, the continuously laid cutting edge does not form a cutting step, resulting in low cutting efficiency. Utility Model Content

[0004] In order to solve the technical problems of poor chip removal, poor cooling and low cutting efficiency caused by continuous laying of cutting material on the wire saw in the background art, the purpose of this utility model is to provide a wire saw structure to solve the above problems.

[0005] The technical solution to achieve the purpose of this utility model is: a wire saw structure, including a core wire, a cutting material, and a binder. The cutting material is covered by the binder around the core wire and forms several cutting segments. The cutting segments are discontinuously distributed along the length direction (i.e., axial direction) of the core wire, and a groove is formed between two adjacent cutting segments.

[0006] In this design, multiple cutting segments are distributed along the core wire. Each segment consists of a solidified material and a covering blade. These segments are intermittently distributed along the core wire, with gaps or grooves between adjacent segments. This allows chips to be discharged through the grooves during cutting, and the grooves also accommodate and facilitate the cooling of the coolant during processing. Furthermore, the spaced-out cutting segments resemble saw teeth, forming cutting steps. The saw-like principle improves cutting efficiency during processing. Through these combined effects, this wire saw structure enhances overall cutting efficiency and quality. It is simple in structure, easy to operate, and widely applicable in wire saw processing. Moreover, when the width of the groove and the diameter of the core wire are within the aforementioned agreed-upon ratios, the overall chip removal, cooling, and cutting performance of the wire saw structure achieves optimal results.

[0007] Furthermore, the shape of the cutting edge segment can be regular or irregular. The distribution of the cutting edge segments along the length direction (i.e., axial direction) of the core wire can be uniform, meaning the groove width W is consistent; or the distribution can be non-uniform, meaning the groove width W can be inconsistent. The cutting edge segments can also be locally connected.

[0008] Furthermore, the core wire can be a single filament or a rope made of multiple twisted single filaments. Its material can be metal or metal alloy, such as carbon steel, stainless steel, tungsten, molybdenum, etc.; or non-metal, such as carbon fiber, aramid fiber, basalt fiber; or composite material. Specifically, the core wire 1 can be made of carbon steel wire, tungsten wire, steel wire rope, steel cord, carbon fiber bundle, etc.

[0009] Furthermore, the cutting material is typically diamond particles, but can also be other high-hardness materials, such as cubic boron nitride particles; the solidified material can be a metal electroplated layer, a resin solidified layer, or brazed metal, sintered ceramics, etc.

[0010] Furthermore, the blade segments are evenly spaced on the core wire, meaning that the grooves between two adjacent blade segments are the same size. The evenly distributed blade segments can ensure the cutting effect.

[0011] Furthermore, several of the blade segments are spirally arranged along the length of the core wire, thus forming a rotating groove, which facilitates the discharge of waste chips and the flow of coolant along the rotating groove.

[0012] Furthermore, the outer diameter of the core wire is D; when the core wire is in the form of a rope, the outer diameter D is the outer diameter of the rope. The width of the groove is W. The width of the cutting edge is Y. 0.08≤W / D≤25, 0.05≤W / Y≤20. Through continuous comparative analysis and experimental results, it has been found that when the width of the groove, the diameter of the core wire, and the width of the cutting edge are within the aforementioned agreed ratios, the overall chip removal, cooling, and cutting performance of the wire saw structure can achieve relatively optimal results.

[0013] Furthermore, the core wire is made of multiple strands of monofilament twisted together, and the binder is resin, which includes an inner layer resin and an outer layer resin. The inner layer resin fills the gaps between the multiple strands of monofilament, and the outer layer resin adheres to the inner layer resin. The cutting edge is located on the outer layer resin. In other words, the gaps between the multiple strands of monofilament are first filled with the inner layer resin, and the outer layer resin and cutting edge are laid after the core wire surface is circumferentially filled. This ensures that the cutting edge is not submerged in the large gaps between the multiple strands of monofilament, preventing the problem that insufficient protruding cutting edge affects cutting and increases costs.

[0014] Furthermore, the side view of the cutting edge along the length of the core wire is rectangular, arc-shaped, trapezoidal, or wavy, etc., selected according to the actual use.

[0015] By adopting the above technical solution, this utility model has the following beneficial effects:

[0016] (1) In this solution, the cutting material is covered with a solidifying agent to form several cutting segments on the outer periphery of the core wire. The cutting segments are discontinuously distributed along the length direction (i.e., axial direction) of the core wire, and a groove is formed between two adjacent cutting segments. This facilitates the discharge of waste chips and the flow of coolant. The cutting segments form cutting steps, similar to a saw, resulting in high cutting efficiency.

[0017] (2) Furthermore, the blade segments are evenly distributed, and the adjacent grooves are all the same size. The uniformly arranged structure can ensure the cutting effect.

[0018] (3) Further limit the width of the groove to the diameter of the core wire and the width of the cutting segment in the above-mentioned ratio relationship to ensure that the chip removal effect, cooling effect and cutting effect can achieve better results.

[0019] (4) When the solidified material is resin, the resin includes an inner layer resin and an outer layer resin. The inner layer resin fills the gap between the hinges of multiple monofilaments, which facilitates the adhesion of the cutting material to the outer layer resin. In this way, the protrusion height of the cutting material on the outer layer resin can be guaranteed, which also ensures the cutting effect, reduces the amount of cutting material sunk in the inner layer resin, and reduces costs.

[0020] (5) The side view shape of the blade segment can be various, such as rectangular, arc, trapezoidal, wave, etc., and can be made according to the actual situation. Attached Figure Description

[0021] To make the content of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein...

[0022] Figure 1 A schematic diagram of the cutting material distribution structure on an existing wire saw;

[0023] Figure 2 This is a schematic diagram of the distribution structure of the cutting edge segment on the core wire composed of multiple monofilaments in this utility model;

[0024] Figure 3 This is a schematic diagram of the distribution structure of the cutting edge segment on the monofilament core wire in this utility model;

[0025] Figure 4 This is a side view schematic diagram of the distribution of the blade segments in this utility model;

[0026] Figure 5This is a schematic diagram of the structure of the cutting edge segment of this utility model, which is spiral-shaped along the core wire axis.

[0027] Figure 6 This is a schematic diagram showing the rectangular shape of the cutting edge section in this utility model from the side.

[0028] Figure 7 This is a schematic diagram showing the arc-shaped side view of the cutting edge section of this utility model.

[0029] Figure 8 This is a schematic diagram of the distribution structure of the inner and outer resin layers in the cross section of the wire saw in this utility model.

[0030] The labels in the attached diagram are: 1 core wire; 2 cutting material; 3 cutting section; 4 groove; 5 inner resin layer; 6 outer resin layer; 7 monofilament; 8 solidified material. Detailed Implementation

[0031] Example 1:

[0032] like Figures 2-3 As shown, this embodiment provides a wire saw structure, including a core wire 1 and a cutting edge 2. The cutting edge 2 is wrapped around the core wire 1 by a binder 8 and aggregated into several cutting segments 3. The cutting segments 3 are discontinuously distributed along the length of the core wire 1, and a groove 4 is formed between adjacent cutting segments 3. The outer diameter of the core wire 1 is D, and the width of the groove 4 is W, where 0.08 ≤ W / D ≤ 25. In this design, multiple bindings 8 are distributed on the core wire 1, with cutting segments 3 composed of cutting edge 2. The discontinuous distribution means that there are gaps or grooves 4 between adjacent cutting segments 3. During cutting, waste chips can be discharged from the grooves 4, and coolant can also be contained in the grooves 4 and driven, thus achieving a better cooling effect. In addition, the spaced cutting segments 3 are similar to the structure of saw teeth, forming cutting steps. During cutting, the saw tooth principle can improve cutting efficiency. Under the mutual promotion of the above structures, the overall cutting efficiency and cutting effect can be improved. The structure is simple, easy to operate, and can be widely applied in wire saw processing. Furthermore, when the width of the groove 4 and the diameter of the core wire 1 are within the aforementioned agreed ratio, the overall chip removal, cooling, and cutting effects of the wire saw structure can achieve relatively optimal results.

[0033] Preferably, the core wire 1 can be a single filament 7 or a rope made of multiple strands of single filaments 7 twisted together. Its material can be metal or metal alloy, such as carbon steel, tungsten, molybdenum, etc.; or non-metal, such as carbon fiber, aramid, basalt fiber; or composite material. The core wire 1 can be made of carbon steel wire, tungsten wire, steel wire rope, steel cord, carbon fiber bundle, etc.

[0034] Preferably, the cutting material 2 can be composed of cubic boron nitride particles, in addition to diamond particles; the solidified material 8 can also be a metal electroplating layer, a resin solidified layer, brazing, ceramic sintering, etc.

[0035] Preferably, the blade segments 3 are evenly spaced on the core wire 1, that is, the grooves 4 between two adjacent blade segments 3 are all the same size, and the evenly distributed blade segments 3 can ensure the cutting effect.

[0036] like Figure 4 As shown, the diameter of the core wire 1 is D, the width of the groove 4 is W, and the width of the cutting edge 3 is Y. 0.08≤W / D≤25, 0.05≤W / Y≤20. Through continuous comparison, analysis, and experimental results, it was found that when the width of the groove 4 and the diameter of the core wire 1 and the width of the cutting edge 3 are within the aforementioned agreed ratios, the overall chip removal, cooling, and cutting performance of the wire saw structure can achieve relatively optimal results.

[0037] like Figure 5 As shown, several of the blade segments 3 are spirally arranged along the length of the core wire 1, thus forming a rotating groove 4, which facilitates the discharge of waste chips and the flow of coolant along the rotating groove 4.

[0038] like Figures 6-7 As shown, the side view of the cutting segment 3 along the length of the core wire 1 is rectangular, arc-shaped, trapezoidal, or wavy, etc., and the shape is selected according to the actual use.

[0039] like Figure 8 As shown, the core wire 1 is made of multiple strands of monofilament 7 twisted together. The binding agent is resin, which includes an inner resin layer 5 and an outer resin layer 6. The inner resin layer 5 wraps around the core wire 1, and the outer resin layer 6 adheres to the inner resin layer 5. The cutting edge 2 is located on the outer resin layer 6. The inner resin layer 5 can also be made of other plastic materials such as polyurethane. That is to say, the gaps between the multiple strands of monofilament 7 are first filled with the inner resin layer 5. After the core wire 1 is filled and its surface is circumferential, the outer resin layer 6 and the cutting edge 2 are then laid. This ensures that the cutting edge 2 is not submerged in the large gaps between the multiple strands of monofilament 7, preventing the problem that a small amount of protruding cutting edge 2 would affect cutting and increase costs.

[0040] Example 2:

[0041] like Figure 2As shown, this embodiment provides a wire saw structure, including a core wire 1 and a cutting edge 2. The cutting edge 2 is covered by a binder 8 around the core wire 1 and aggregated into several cutting segments 3. The cutting segments 3 are discontinuously distributed along the length of the core wire 1, and a groove 4 is formed between adjacent cutting segments 3. The core wire 1 is a 1x7 high-strength steel wire rope with a diameter D of 2.0 mm. The cutting edge 2 is diamond particles. The binder 8 is a nickel electroplated layer, which electroplats the diamond particles of the cutting edge 2 onto the steel wire rope of the core wire 1. Through discontinuous electroplating, the nickel layer of the binder 8 is discontinuously distributed on the steel wire rope of the core wire 1, forming multiple discontinuous cutting segments 3. The width Y of the cutting segment 3 is 4.2 mm, the width W of the groove 4 between the cutting segments 3 is 1.6 mm, and the depth of the groove, which is also the height of the cutting segment, is 0.25 mm. In this way, during cutting, waste chips can be discharged from the groove 4, and more coolant can be contained within the groove 4, providing better cooling for the machined surface and the wire saw. Furthermore, the spaced-out cutting segments, similar to saw teeth, form cutting steps, which improves cutting efficiency due to the saw-tooth principle. The synergistic effect of these structures enhances both overall cutting efficiency and cutting effect.

[0042] Working principle: Multiple blade segments 3, consisting of a solidified material 8 and a cutting edge 2, are evenly distributed on the surface of the core wire 1, forming a stepped, serrated structure that provides excellent cutting performance. During cutting, the grooves 4 between adjacent blade segments 3 facilitate the discharge of waste chips and the flow of coolant. When the solidified material 8 is made of resin, the gaps between the multiple strands of monofilament 7 are first filled with an inner layer of resin 5. After the core wire 1 is filled and its surface is circumferential, the outer layer of resin 6 and the cutting edge 2 are then laid. This ensures that the cutting edge 2 is not submerged in the large gaps between the multiple strands of core wire 1, preventing issues such as insufficient resin protrusion affecting cutting and higher costs.

[0043] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this utility model. It should be understood that the above descriptions are merely specific embodiments of this utility model and are not intended to limit this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A wire saw structure, characterized in that, It includes a core wire (1) and a cutting edge (2). The cutting edge (2) is covered by a binder (8) around the core wire (1) and forms several cutting segments (3). The cutting segments (3) are discontinuously distributed along the length of the core wire (1), and a groove (4) is formed between two adjacent cutting segments (3). The outer diameter of the core wire (1) is D, and the width of the groove (4) is W, 0.08≤W / D≤25. The width of the cutting edge (3) is Y, and the width of the groove (4) is W, 0.05≤W / Y≤20.

2. The wire saw structure according to claim 1, characterized in that, Several of the blade segments (3) are evenly spaced on the core wire (1).

3. The wire saw structure according to claim 1, characterized in that, The core wire (1) is made of multiple strands of monofilament (7) twisted together. The binder (8) is resin, which includes an inner layer resin (5) and an outer layer resin (6). The inner layer resin (5) fills the gaps between the multiple strands of monofilament (7), and the outer layer resin (6) adheres to the inner layer resin (5). The blade material (2) is located on the outer layer resin (6).

4. The wire saw structure according to claim 1, characterized in that, Several of the blade segments (3) are spiral in shape along the length direction of the core wire (1).

5. The wire saw structure according to claim 1, characterized in that, The side view of the blade segment (3) along the length of the core line (1) is rectangular, arc-shaped, trapezoidal, or wavy.

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