Matrix-free diamond bead string and wire saw

Abstract

The utility model discloses a kind of matrixless diamond string beads and rope saw, belong to diamond tool element technical field.The utility model discloses the matrixless diamond string beads including diamond string bead body, the diamond string bead body is annular structure, recess is set with diamond string bead body coaxial in the upper and lower ends of diamond string bead body, the caliber of the recess entrance end is greater than its caliber with diamond string bead body connecting end, and less than the outer diameter of diamond string bead body;The diamond string bead body is sintered after forming by matrix powder containing diamond abrasive grain and metal or alloy powder.The matrixless diamond string beads provided by the utility model can ensure the bonding force of diamond string bead and steel wire rope under the condition of reducing the amount of organic binder, reduce the occurrence of string bead, rope breaking phenomenon in the use process of diamond rope saw.

Description

Technical Field

[0001] This utility model relates to the technical field of diamond tool components, specifically to a matrix-free diamond bead and wire saw. Background Technology

[0002] Diamond wire saws, as flexible cutting tools, are widely used in stone quarrying, block processing, reinforced concrete construction, non-ferrous metal mining, and special metal processing. Their working principle involves the diamond wire saw moving in a closed-loop high-speed circular motion driven by guide wheels. The diamonds on the surface of the diamond beads grind or cut the workpiece, thus achieving the machining process. Diamond wire saws mainly consist of a steel wire rope, fixing materials, and diamond beads. The manufacturing process involves inserting diamond beads, soaked or sprayed with an organic adhesive (such as Chemlock), onto the steel wire rope. Fixing materials (such as plastic, rubber, plastic + spring, spring + rubber, etc.) are used to fix the diamond beads to the steel wire rope at certain intervals through injection molding or compression molding, thus completing the manufacturing of the diamond wire saw.

[0003] Conventional diamond beads are cylindrical (cylindrical) in shape, consisting of a cylindrical base and a matrix surrounding the base. The base is typically made of steel or copper, while the matrix, serving as the working layer, is formed by cold-pressing a matrix powder containing diamond abrasive grains and metal or alloy powder onto the base. This traditional structure has the following drawbacks due to the necessity of the base: 1) Reduced radial space and thickness of the working layer, decreasing its effective utilization rate; 2) The exposed ends of the base are longer than the matrix, making the softer base prone to deformation and cracking during cutting, leading to bead breakage and accidents; 3) The matrix and base require sintering, which can create defects at the joint, causing the matrix to detach from the base and resulting in production accidents; 4) Increased base pressing is required during cold pressing. To ensure the bonding strength between the base and the steel wire rope, secondary processing such as countersinking and tapping is necessary after cold pressing and sintering, adding to the cold pressing and subsequent processing steps; 5) The presence of the base increases raw material costs; 6) ... Applying chemical organic adhesives to the inner pores of the bead matrix to enhance bonding strength poses a potential health hazard to operators during the production process, hindering the diamond wire saw industry from moving towards green production; 7) As diamond wire saws are flexible cutting tools that drive the cutting object through guide wheels, stress is generated between the rigid matrix end and the wire rope when the wire saw passes the guide wheel or the object during the cutting process, causing the wire rope to wear and break; Furthermore, during the plastic sealing and glue sealing processes of diamond wire saws, the position of the wire rope in the matrix hole may become eccentric, causing the rigid matrix end to come into direct contact with the wire rope, which may break prematurely due to stress during cutting.

[0004] Based on the above shortcomings, matrix-free beaded beads have emerged. A search revealed:

[0005] The invention patent with publication number CN102825254A discloses a diamond bead, a preparation method, and a diamond bead wire saw that does not require a matrix support layer. The diamond bead does not require a matrix layer. The rough blank is sintered into an integral cylindrical bead in one go. The outer diameter of the bead is reduced, and a diamond wire saw with a smaller outer diameter can be made by directly threading a steel wire rope through it. Since the bead is formed in one go, there is no need for a subsequent penetration process, which greatly reduces the production cost of diamond beads.

[0006] Patent CN119634834A discloses a small-diameter diamond wire saw, comprising a steel wire rope and multiple sets of beads fixedly sleeved on the steel wire rope. Each set of beads includes at least one thick ring and at least one thin ring, with the thick and thin rings having the same outer diameter, and the thickness of the thick ring being 2 to 5 times that of the thin ring. The thick and thin rings are arranged alternately on the steel wire rope, and the thick and thin rings of the multiple sets of beads are fixedly connected to the steel wire rope through an injection molding layer. The thick and thin rings constituting the beads are both matrix-free structures. In this invention, the thick and thin rings constituting the beads are designed as ring-shaped structures, ensuring product lifespan while also achieving high cutting efficiency; furthermore, because the beads do not contain a matrix, the manufacturing process is simple.

[0007] The aforementioned diamond beads, by eliminating the need for a matrix, reduce production steps and lower costs, and increase the radial thickness of the working layer of the matrix, thereby improving the utilization rate of the diamond wire saw. However, the structure of the aforementioned diamond beads is a straight cylindrical hollow structure, with the inner hole of the hollow part being a cylindrical through hole with the same upper and lower diameters. On the one hand, during the forming process of fixing the diamond beads to the wire rope, the fixing material cannot fill the gap between the beads and the wire rope to a greater extent, especially at the ends of the diamond beads. Therefore, the bonding force between the beads and the wire rope relies solely on the organic adhesive or the organic adhesive and a small amount of fixing material. Due to the high-speed movement during use, diamond wire saws are prone to the phenomenon of the beads shifting on the wire rope (i.e., bead slippage). To improve the bonding force between the diamond beads and the wire rope, it is necessary to increase the amount of organic adhesive, which will increase costs. On the other hand, when using a diamond wire saw, the ends of the diamond beads are in direct contact with the wire rope, and there is still a certain stress between the diamond beads and the wire rope. The ends of the diamond beads and the parts of the wire rope in contact with the ends of the diamond beads will be worn and damaged, which not only consumes the working layer of the diamond bead matrix, but also easily causes the wire rope to break. Utility Model Content

[0008] The technical problem to be solved by this utility model is to provide a matrix-free diamond bead and wire saw. The diamond bead of this structure can ensure the bonding force between the bead and the wire rope while reducing the amount of organic adhesive used, thereby reducing the occurrence of bead slippage and rope breakage during the use of the diamond wire saw.

[0009] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0010] A matrix-free diamond bead includes a diamond bead body, characterized in that the diamond bead body has a ring structure, and grooves coaxial with the diamond bead body are formed at both the upper and lower ends of the diamond bead body. The diameter of the inlet end of the groove is larger than the diameter of the end connecting with the diamond bead body, but smaller than the outer diameter of the diamond bead body. The diamond bead body is formed by molding and sintering a matrix powder containing diamond abrasive grains and metal or alloy powder.

[0011] Furthermore, the longitudinal cross-sectional shape of the groove is rectangular, trapezoidal, stepped, bowl-shaped, or irregular.

[0012] Furthermore, the grooves at the upper and lower ends of the diamond bead body are symmetrical along the horizontal cross-section passing through the midpoint of the centerline of the diamond bead body.

[0013] Furthermore, the inner hole of the diamond bead body is a cylindrical through hole with the same upper and lower diameters, or a drum-shaped through hole with a small middle diameter and large diameters at both ends.

[0014] This utility model also provides a matrix-free diamond wire saw, including a steel wire rope and diamond beads fixedly sleeved on the steel wire rope, wherein the diamond beads are matrix-free diamond beads with the above-described structure.

[0015] Compared with the prior art, the diamond beads of this utility model have an inorganic matrix structure, which is formed and sintered from matrix powder containing diamond abrasive grains and metal or alloy powder. By opening grooves coaxial with the diamond bead body at both the upper and lower ends of the diamond bead body, and limiting the diameter of the groove entrance end to be larger than the diameter of the end connecting with the diamond bead body but smaller than the outer diameter of the diamond bead body, more fixing material can be filled in the gap between the ends of the diamond bead body and the steel wire rope, thereby improving the bonding force between the diamond bead and the steel wire rope. Therefore, the amount of organic adhesive can be reduced, and the bonding force between the diamond bead and the steel wire rope can be maintained while reducing the amount of organic adhesive, thus reducing the occurrence of bead slippage during the use of the diamond wire saw. On the other hand, due to the specially designed grooves at both ends of the diamond bead body, the diamond wire saw first grinds and cuts the fixing material filling the grooves at both ends of the diamond bead, thus reducing wear on the working layer of the diamond bead matrix. Furthermore, since the fixing material has a lower hardness than the working layer of the matrix, the stress on the wire rope is also relatively reduced, thus decreasing the likelihood of wire rope breakage. Finally, the design of the groove inlet diameter being larger than the connection port diameter with the diamond bead body effectively prevents magma water from entering the diamond bead, thereby preventing magma water from corroding the wire rope; at the same time, the wire rope will not be damaged by the bending of the diamond bead during use. Attached Figure Description

[0016] Figure 1 This is a cross-sectional schematic diagram of a matrix-free diamond bead with a trapezoidal longitudinal cross-section of the groove.

[0017] Figure 2 This is a cross-sectional schematic diagram of a matrix-free diamond bead with a rectangular longitudinal section of groove.

[0018] Figure 3 This is a cross-sectional schematic diagram of a matrix-free diamond bead with a stepped longitudinal cross-section of the groove.

[0019] Figure 4 This is a cross-sectional schematic diagram of one embodiment of a matrix-free diamond bead with a bowl-shaped longitudinal cross-section of the groove.

[0020] Figure 5 This is a cross-sectional schematic diagram of another embodiment of a matrix-free diamond bead with a bowl-shaped longitudinal cross-section of the groove.

[0021] Figure 6 This is a cross-sectional schematic diagram of a matrix-free diamond bead with an irregular longitudinal cross-sectional shape of the groove.

[0022] Figure 7 To adopt Figure 1A cross-sectional schematic diagram of the diamond wire saw product prepared according to the embodiment shown.

[0023] The numbers on the map are:

[0024] 1. Matrix-free diamond beads, 11. Inner hole, 12. Groove, 2. Steel wire rope, 3. Fixing material. Detailed Implementation

[0025] To better explain the technical solution of this utility model, the following describes the utility model in further detail with reference to the embodiments, but the embodiments of this utility model are not limited thereto.

[0026] The matrix-free diamond bead 1 of this utility model includes a diamond bead body, which has a ring structure. At both the upper and lower ends of the diamond bead body, there are grooves 12 that are coaxial with the diamond bead body and recessed into the middle of the diamond bead body. The diameter of the inlet end of the groove 12 is larger than the diameter of the end that connects to the diamond bead body, but smaller than the outer diameter of the diamond bead body. The diamond bead body is formed by molding and sintering a matrix powder containing diamond abrasive grains and metal or alloy powder.

[0027] In the technical solution described in this utility model, the composition and proportion of the matrix powder are the same as those used in the working layer of the matrix in the prior art with or without matrix diamond beads.

[0028] The matrix-free diamond bead 1 described in this invention has the same dimensions as existing matrix-containing or matrix-free diamond beads 1. Specifically, the height of the matrix-free diamond bead 1 described in this invention is 3.0~11.0mm.

[0029] The grooves 12 at both ends of the diamond bead body can be of any shape, provided that the aforementioned limitations are met. In some preferred embodiments, the longitudinal cross-sectional shape of the groove 12 can be trapezoidal, rectangular, stepped, bowl-shaped, or irregularly shaped. Specifically, when the longitudinal cross-sectional shape of the groove 12 is trapezoidal... Figure 1 As shown, when the longitudinal cross-sectional shape of the groove 12 is rectangular, ... Figure 2 As shown, when the longitudinal cross-sectional shape of the groove 12 is stepped, such as... Figure 3 As shown, when the longitudinal cross-sectional shape of the groove 12 is bowl-shaped, as Figure 4 and Figure 5 As shown, when the longitudinal cross-sectional shape of the groove 12 is a sawtooth irregular shape, such as... Figure 6 As shown.

[0030] The inlet end of the groove 12 is the end flush with the end face of the diamond bead body, and the other end of the groove 12 is the connection end between the groove 12 and the diamond bead body. The diameter of the connection end between the groove 12 and the diamond bead body should be greater than or at least equal to the diameter of the inner hole 11 of the diamond bead body. The inner hole 11 of the diamond bead body allows the steel wire rope 2 to pass through; therefore, the shape and size of the inner hole 11 only need to be compatible with the steel wire rope 2. Preferably, the inner hole 11 is a cylindrical through hole with the same upper and lower diameters, or a drum-shaped through hole with a smaller diameter in the middle and larger diameters at both ends. When the inner hole 11 is a drum-shaped through hole, the largest diameter in the drum-shaped through hole is used as the diameter of the inner hole 11 of the diamond bead body.

[0031] The connection between the groove 12 and the diamond bead body can be a right-angle transition or an arc transition.

[0032] The depth of the grooves 12 at the upper and lower ends of the diamond bead body along the axial direction of the diamond bead body can be adjusted as needed, usually 0.2~3.0mm. The depths of the grooves 12 at the upper and lower ends can be the same or different.

[0033] The grooves 12 at the upper and lower ends of the diamond bead body can have the same or different shapes. In a preferred embodiment, the grooves 12 at the upper and lower ends of the diamond bead body have the same shape and are symmetrical along the horizontal cross-section passing through the midpoint of the centerline of the diamond bead body.

[0034] Furthermore, this utility model also provides a matrix-free diamond wire saw, including a steel wire rope 2 and diamond beads fixedly sleeved on the steel wire rope 2, wherein the diamond beads are matrix-free diamond beads 1 with the above-described structure.

[0035] Specific embodiment 1: Diamond beads and diamond wire saw with a trapezoidal longitudinal cross-sectional shape for groove 12.

[0036] See Figure 1 As shown, the diamond bead body has a ring structure. The inner hole 11 of the diamond bead body is a cylindrical through hole with the same upper and lower diameters. At both the upper and lower ends of the diamond bead body, there are grooves 12 that are coaxial with the diamond bead body and recessed into the middle of the diamond bead body. The longitudinal cross-sectional shape of the grooves 12 at both the upper and lower ends of the diamond bead body is trapezoidal, and the horizontal cross-sections passing through the midpoint of the centerline of the diamond bead body are symmetrical to each other.

[0037] A 4.9mm copper-plated steel wire rope 2 is selected, and a trapezoidal longitudinal cross-section of Ø12.5mm is designed to be used to prepare sintered beads using existing cold pressing methods. The height of the diamond bead body is 7.0mm, the diameter of the inner hole 11 on the diamond bead body is 5.2mm, the diameter of the entrance end of the groove 12 at both ends of the diamond bead body is 8.0mm, the diameter of the end connecting to the diamond bead body is 5.2mm, and the depth of the groove 12 in the axial direction of the diamond bead body is 3.0mm. The diamond beads are threaded into the steel wire rope 2. A mold of 40 beads per meter is selected, and rubber with a Shore hardness of 78~82HA is used as the fixing material 3. The diamond wire saw is prepared by injection molding using a sealing device. Figure 7 As shown.

[0038] Specific embodiment 2: Diamond beads with a rectangular longitudinal cross-sectional shape for groove 12.

[0039] See Figure 2 As shown, the diamond bead body has a ring structure. The inner hole 11 of the diamond bead body is a cylindrical through hole with the same upper and lower diameters. At both the upper and lower ends of the diamond bead body, there are grooves 12 that are coaxial with the diamond bead body and recessed into the middle of the diamond bead body. The longitudinal cross-sectional shape of the grooves 12 at both the upper and lower ends of the diamond bead body is rectangular, and the horizontal cross-sections passing through the midpoint of the centerline of the diamond bead body are symmetrical to each other.

[0040] Specific embodiment 3: Diamond beads with a bowl-shaped longitudinal cross-section of groove 12.

[0041] See Figure 4 As shown, the diamond bead body has a ring structure. The inner hole 11 of the diamond bead body is a cylindrical through hole with the same upper and lower diameters. At both the upper and lower ends of the diamond bead body, there are grooves 12 that are coaxial with the diamond bead body and recessed into the middle of the diamond bead body. The longitudinal cross-sectional shape of the grooves 12 at both the upper and lower ends of the diamond bead body is bowl-shaped, and the horizontal cross-sections along the midpoint of the center line of the diamond bead body are symmetrical to each other.

[0042] Specific embodiment 9: Diamond beads with an irregular longitudinal cross-sectional shape for groove 12.

[0043] See Figure 6 As shown, the diamond bead body has a ring structure. The inner hole 11 of the diamond bead body is a cylindrical through hole with the same upper and lower diameters. At both the upper and lower ends of the diamond bead body, there are grooves 12 that are coaxial with the diamond bead body and recessed into the middle of the diamond bead body. The longitudinal cross-sectional shape of the grooves 12 at both the upper and lower ends of the diamond bead body is a serrated irregular shape, and the horizontal cross-sections along the midpoint of the center line of the diamond bead body are symmetrical to each other.

[0044] Experimental Example

[0045] A diamond wire saw, further prepared using the matrix-free diamond beads 1 described in Specific Embodiment 1, was used as a cutting tool. A commercially available brand of diamond wire saw (whose diamond beads are matrix-bound diamond beads, and the outer diameter of the matrix-bound diamond beads is the same as that of the matrix-free diamond beads described in Embodiment 1) was used as a control. The saws were installed on a ZSJ92 machine from Nanhui Factory in Nan'an, Fujian Province. Granite of the same size was used as the cutting object, and five pieces of each saw were cut using the same operation for a comparative cutting experiment, totaling six cuts. The test results showed that the commercially available brand of diamond wire saw experienced one wire breakage during the third cut, while the diamond wire saw described in Embodiment 1 of this invention did not experience any wire breakage throughout the entire process.

Claims

1. A matrix-free diamond bead (1), comprising a diamond bead body, characterized in that, The diamond bead body has a ring structure. Grooves (12) coaxial with the diamond bead body are provided at both the upper and lower ends of the diamond bead body. The diameter of the inlet end of the groove (12) is larger than the diameter of the end connected to the diamond bead body, and smaller than the outer diameter of the diamond bead body. The diamond bead body is formed by molding and sintering a matrix powder containing diamond abrasive grains and metal or alloy powder.

2. The matrix-free diamond bead (1) according to claim 1, characterized in that, The longitudinal cross-sectional shape of the groove (12) is rectangular, trapezoidal, stepped, bowl-shaped or irregular.

3. The matrix-free diamond bead (1) according to claim 1 or 2, characterized in that, The grooves (12) at the upper and lower ends of the diamond bead body are symmetrical to each other along the horizontal cross section passing through the midpoint of the center line of the diamond bead body.

4. The matrix-free diamond bead (1) according to claim 1 or 2, characterized in that, The inner hole (11) of the diamond bead body is a cylindrical through hole with the same upper and lower diameters, or a waist drum-shaped through hole with a small middle diameter and large two-end diameters.

5. A matrix-free diamond wire saw, comprising a steel wire rope (2) and diamond beads fixedly sleeved on the steel wire rope (2), characterized in that, The diamond beads mentioned herein are matrix-free diamond beads (1) as described in any one of claims 1 to 4.

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