Wire Saw Slice Retrieval Vibration
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Solution Overview
Problem
Existing wire saw processes face challenges with stick-and-slip movements of the Sägel wire during Ingot Retrieval, leading to quality issues such as notches on the slices and potential wire tears, which are time-consuming and costly to resolve.
Innovation Solution
A procedure involving the simultaneous separation of slices using a wire saw, where the workpiece is moved perpendicular to a wire gate with a coolant lubricant, and the slices are pulled out while the separation column is sprayed with a liquid using nozzles that oscillate parallel to the workpiece axis, stimulating slice vibration through the Bernoulli effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the bar and discs are pulled out of the wire frame during ingot retrieval, then the sliced workpiece can be removed from the wire saw, but stick-and-slip movements of the saw wire occur causing notches on slices and potential wire tears
Solution Approach 1:
The patent applies high-frequency vibration to the saw wire during ingot retrieval to prevent stick-and-slip movements. The vibration device generates vibrations that keep the saw wire continuously moving relative to the workpiece, eliminating the stick-slip phenomenon that causes notches and wire tears, thereby maintaining slice quality while enabling efficient retrieval
Solution Approach 2:
The patent introduces a dynamic element by making the saw wire vibratable during the retrieval process. Instead of a static retrieval operation, the system dynamically adjusts the wire's motion state through vibration, allowing the wire to adapt to the retrieval process without causing damage to slices or itself
2Productivity
If cooling lubricant is supplied to the wire frame during cutting, then cutting performance is improved, but additional complexity is introduced to the system
Solution Approach 1:
The cooling lubricant supply system serves multiple functions simultaneously: it cools the wire frame, lubricates the cutting interface, and helps flush away cuttings. This multi-functionality justifies the added complexity by delivering multiple benefits from a single integrated system component
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 reduces frictional forces during Ingot Retrieval and slice repositioning, preventing stick-and-slip movements and associated quality issues, while ensuring efficient separation and retrieval of high-quality slices.
Implementation Method 1
the liquid and entrained air temporarily excite the discs to oscillate
Implementation Method 2
a cooling lubricant is supplied to the wire frame
Data Source
Figure 1
Figure 2(A)~2(B)
AI summary
A method for simultaneously separating a plurality of discs (34) from a workpiece (1) by means of a wire saw, comprising a cutting-grinding operation, wherein a workpiece (1) is positioned perpendicular to a longitudinal axis (26) of the workpiece against a wire gate (24) of a saw wire (4) stretched between two wire guide rollers (5, 6) and moved in the longitudinal direction of the saw wire, wherein a cooling lubricant is supplied to the wire gate (24), and wherein discs (34) are formed between wire sections of the wire gate (24), which are attached to a bar (2) and between which cutting gaps (22) exist, and the bar (2) and the discs (34) are withdrawn from the wire gate (24), wherein during the withdrawal of the bar (2) and the discs (34) the cutting gaps (22) are sprayed with a liquid (21) by means of a spray device until the wire sections have left the cutting gaps (22),wherein the liquid (21) is supplied under high pressure through nozzles (14) which are attached to nozzle bars (16, 17) which are moved in an oscillating manner parallel to the longitudinal axis (26) of the workpiece (1), wherein the liquid (21) and entrained air (35) temporarily excite the disks (34) to vibrate.