Wire Saw Coolant Switching to Prevent Workpiece Catching
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Solution Overview
Problem
In wire saws using fixed abrasive grain wires, the sliced workpiece often catches the wire, leading to saw marks and wire disconnection during extraction, due to the narrow clearance between the wire and the workpiece, resulting in quality degradation and increased re-winding requirements.
Innovation Solution
A method involving a wire saw with a fixed abrasive grain wire wound around grooved rollers, where a coolant with a higher viscosity than used during slicing is applied during workpiece extraction to enhance lubricity and prevent wire catching, using a coolant with a viscosity of 15 mPas or more for drawing and 5 mPas or less for slicing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fixed abrasive grain wire is used for slicing, then the processing rate is improved and environmental waste is reduced, but the clearance between the wire and workpiece becomes narrow causing the wire to catch on the workpiece during extraction
Solution Approach 1:
The patent changes the viscosity parameter of the coolant from low viscosity (during slicing) to high viscosity (during extraction). This parameter change allows the coolant to provide enhanced lubrication during the extraction phase, reducing friction between the fixed abrasive grain wire and the workpiece, thereby preventing wire catching while maintaining the productivity benefits of fixed abrasive grains
2Productivity
If a fixed abrasive grain wire is used for slicing, then the processing rate is improved, but saw marks are formed on the workpiece and wire disconnection occurs during extraction
Solution Approach 1:
The patent applies parameter changes by switching from low viscosity coolant to high viscosity coolant during the extraction phase. This viscosity change enhances the lubricating film between the wire and workpiece, preventing direct contact that would cause saw marks and wire disconnection, thereby maintaining manufacturing precision while preserving the high processing rate advantage
Solution Approach 2:
The patent applies preliminary action by supplying the high viscosity coolant before the extraction process begins. This ensures that the lubricating film is already in place on the wire and workpiece contact surfaces before extraction starts, preventing saw marks and wire disconnection from occurring during the extraction operation
3Device complexity
If the same coolant is used for both slicing and extraction, then the process is simplified, but the wire catches on the workpiece during extraction due to insufficient lubrication
Solution Approach 1:
The patent applies segmentation by dividing the coolant supply process into two distinct phases: slicing phase with low viscosity coolant and extraction phase with high viscosity coolant. This segmentation allows each phase to use the optimal coolant properties for its specific function, improving extraction ease without significantly increasing overall system complexity through separate coolant delivery mechanisms
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively inhibits saw marks and wire disconnection, maintaining slicing quality and reducing re-winding needs by improving lubricity during workpiece extraction with the higher viscosity coolant.
Implementation Method 1
supplying a coolant for workpiece drawing, which is different from the coolant for workpiece slicing and has a higher viscosity than the coolant for workpiece slicing, onto the wire row when the workpiece is drawn out from the wire row after the slicing of the workpiece
Implementation Method 2
a coolant for workpiece drawing, which is different from the coolant for workpiece slicing and has a higher viscosity than the coolant for workpiece slicing
Data Source
AI summary
A method for slicing a workpiece with a wire saw which includes a wire row formed by winding a fixed abrasive grain wire having abrasive grains secured to a surface thereof around multiple grooved rollers, the method including feeding a workpiece to the wire row for slicing while allowing the fixed abrasive grain wire to reciprocatively travel in an axial direction thereof, thereby slicing the workpiece at multiple positions aligned in an axial direction of the workpiece simultaneously. The method includes: supplying a coolant for workpiece slicing onto the wire row when the workpiece is sliced with the fixed abrasive grain wire; and supplying a coolant for workpiece drawing, which differs from and has a higher viscosity than the coolant for workpiece slicing, onto the wire row when the workpiece is drawn out from the wire row after the slicing of the workpiece.