With the developing of stone material, diamond saw pl ate is used widely, and in order to increase cutting efficiency and life-span o f diamond saw plate, there are a lot of research jobs of segment for diamond saw pl...With the developing of stone material, diamond saw pl ate is used widely, and in order to increase cutting efficiency and life-span o f diamond saw plate, there are a lot of research jobs of segment for diamond saw plate. Layered segment for diamond saw plate is to divide single segment into s everal cutting tools by its structure, then increases rock-cutting faces. For i mpregnated man-made diamond saw plate, the bonding strength of diamonds with ma trix material has great effect on its life and service. Diamond is a kind of non metal and there is such high interface energy between diamond and common metals or alloys that diamond surface can’t be soaked by low melt-point metal or allo y. Diamonds are hold in metal matrix of working layer only mechanically, rather than bonded chemically, so the usage rate of diamonds in working layer is very l ow. Weakly impregnated method refers to covering diamonds with a thin layer of tu ngsten carbide mechanically by physical method, and chemical plating membrane re fers to coating a layer of carbide, which can react with the carbon atoms on the surface of diamond by chemical method and be soaked by matrix metal. In this pa per it analyses working mechanism and sintering process of layered segment of di amond saw plate by means of resistor hot-pressing sintering, it points out shor tages of layered structure, and raises using weakly impregnated layer instead of pure matrix layer, then overcomes the pure matrix layer slipping by pulling out diamonds earlier to improve cutting efficiency of saw plate, in the same time u ses diamond grains of chemical plating membrane proposed then preventing the hea t-hurting to diamond grains in working layer during the process of welding and sintering and improving the bonding strength of diamond with matrix, then improv ing life-span and aging of diamond saw. The theory of the design of mixed holding of diamonds by matrix of saw plate assures that chemical plating diamonds in working layer cut rock and weakly impr egnated diamonds in weakly impregnated layer make segment expose, then design a new type of layered segment for diamond saw plate.展开更多
The FEM analysis of stress and deformation of steel base of the special diamond saw blades are carried out.The small carbide round segments are welded on the side of blades in order to increase the side wear re sistan...The FEM analysis of stress and deformation of steel base of the special diamond saw blades are carried out.The small carbide round segments are welded on the side of blades in order to increase the side wear re sistance of blade.Comparing with conventional saw blade,the maximum stress val ues of reasonable special saw blade are reduced respectively about 17%20% 33%,and the maximum deformation values are reduced respectively about 26%22 %44.7%in thetangential(X),radial(Y)and axial(Z)direction.The stress conce ntration zone is decreased for the special structure diamond saw blade.The stru ctures of diamond saw blade with different number of hard material pellet are an alyzed and optimized.展开更多
An experimental study was carried out to quantitati ve ly evaluate the loads acting on the diamond grits during circular sawing of two kinds of typical granite with diamond segmented saw blade. Measurements were mad e...An experimental study was carried out to quantitati ve ly evaluate the loads acting on the diamond grits during circular sawing of two kinds of typical granite with diamond segmented saw blade. Measurements were mad e of the horizontal and vertical force components and the consumed power in order to obtain the tangential and the normal force components. The temperatures at the diamond-granite contact zone were measured using a foil thermocouple. T he measurement, together with the net sawing power, was subsequently used to est imate the energy partition to the granite by a temperature matching technique. B ased on the energy partition values, the temperatures at individual cutting poin ts were estimated using an analytical model. SEM was used to follow the topograp hies of worn diamond segments. The average force acting on each diamond grit was found to be only 4% of the diamond compressive strength measured by a static me thod. The strength disparity of diamond grits and the random protrusion of grits beyond bond matrix should be significant factors in accounting for the wear of diamond grits. The wear of diamond grits was also found to be closely related to the high temperatures generated at individual cutting points and the pop-outs of diamonds from the bond matrix might be mainly attributed to the heat conducte d to the segments.展开更多
The heated test pieces were treated with alternating magnetic field by self-made experimental facility firstly. And influences of magnetic treatment on microstructure densification of Diamond Saw Segments were studied...The heated test pieces were treated with alternating magnetic field by self-made experimental facility firstly. And influences of magnetic treatment on microstructure densification of Diamond Saw Segments were studied through hardness testing, ultrasonic testing, metallurgical structure and fracture pattern analysis by comparative method. The mechanism of magnetic treatment is analyzed and discussed in the end. The results show that the hardness of test pieces after magnetized are harder than before, that HRB hardness is improved by 3.58 on average. The sound path and amplitude of echo wave both decrease in test pieces after magnetized. The relative pad value of echo wave is regularly related with the microstructure densification, what is profound to further establish the regularity studying the degree of matrices densification using ultrasonic testing. The pores become few and pore shape gradually spheroidizing with the magnetic treatment, and matrices are more homogeneous and compact than the without by metallographic microscope. The degree of matrices densification is further improved after magnetized. The average crystal grain size is finer than the without, and the reason of grain refining is that densification of diamond saw blade improved. Magnetic treatment can act as one kind of effective technique to improve the microstructure densification of diamond saw segments.展开更多
Based on impulse and vibration machining theories,a mathematical model of cutting force for the electroplated diamond ultrasonic wire saw was established using superposition principle.The differences between the cutti...Based on impulse and vibration machining theories,a mathematical model of cutting force for the electroplated diamond ultrasonic wire saw was established using superposition principle.The differences between the cutting forces with and without ultrasonic effect were analyzed theoretically and experimentally.The results indicate that the cutting force of diamond wire increases along with the spindle speed decrease and the lateral pressure increase.The force in ultrasonic vibration cutting is about 20% to 30% less than that in conventional cutting.Also,the cutting trajectory of single diamond grit in sawing process is simulated,and the reason that the ultrasonic vibration can reduce the cutting force is explained further.展开更多
The diamond wire-sawing process was developed to cut granite in both quarries and block processing plants.In this paper,swarf was collected from different areas along the sawing arc when sawing three granites.The part...The diamond wire-sawing process was developed to cut granite in both quarries and block processing plants.In this paper,swarf was collected from different areas along the sawing arc when sawing three granites.The particle size distribution and the morphology of the swarf were investigated systematically,along with the swarf formation mechanism in sawing.Granite swarf formation was dominated by transgranular fractures based on the morphology of sawn granite chips and the analysis of sawn chip size.A long cutting arc increased the movement among the swarf,tool,and workpiece,thereby inducing a secondary fracture in the sawn chip.展开更多
Diamond grits are indispensable for sawing granite or concrete.Each year about 1 000 tons of diamond grits are consumed for such purposes.In all cases,mono crystalline diamond is used.However, polycrystalline grits(po...Diamond grits are indispensable for sawing granite or concrete.Each year about 1 000 tons of diamond grits are consumed for such purposes.In all cases,mono crystalline diamond is used.However, polycrystalline grits(polygrits) are generally better performed than mono grits as abrasives.For example,poly grits of cubic boron nitride(e.g.Borazon(?) CBN-550 of Diamond Innovations) can cut faster and they last longer than mono grits(e.g.Borazon(?) CBN-500). Polygrits of alumina(e.g.Cubitron(?) of 3M) also out perform by far glassy grits(e.g.white alumina).For diamond superabrasives,micron polygrits formed by shock waves may polish as fast as mono grits of the same size,but without causing as much scratches due to the presence of smaller sintered grains.The improved performance of poly grits is attributed to their ability to micro chipping that renews the sharp cutting corners from time to time.By contrast,mono grits tend to round off at low cutting force or macro fracture at high cutting force,so they may lose the cutting ability rapidly. For sawing granite with mesh sizes 40/50 or coarser,poly grits of diamond have not been available until recently.In this research,we have made polygrits in mini cube with sizes of 18/20,20/25,and 30/40.Turbo grinders and wire saws were made by brazing both mono grits and polygrits on steel substrates.Cutting performance on granite demonstrated that grinding speed was faster with turbo grinder,and the surface finish was smoother with wire saw for poly grits than mono ones. Polygrits and mono grits of diamond were mixed for comparison(upper left).Polygrits of mini cubes were brazed on the pearl of a wire saw(upper right).Mono diamond grits were brazed on a turbo grinder(bottom diagrams ).展开更多
Four wear modes and four wear mechanisms of diamonds in sawblades are identified in a study of varied segments damaged in field operation of sawing hard stone. The four wear mechanisms are impactshearing, fatiguing, p...Four wear modes and four wear mechanisms of diamonds in sawblades are identified in a study of varied segments damaged in field operation of sawing hard stone. The four wear mechanisms are impactshearing, fatiguing, pullingout and thermal effects. Surface erosion is the result of thermal effects, while impactshearing and fatiguing lead to macro and microfracture, and pullingout results in wholesale dislodgement of diamonds provided the inequality Fn>M/(μλδ) is satisfied.展开更多
The influence of different technological parameter on material remove rate and surface quality of ZrO2 ceramics is studied using the cutting machining method of electroplate diamond wire saw with ultrasonic vibration....The influence of different technological parameter on material remove rate and surface quality of ZrO2 ceramics is studied using the cutting machining method of electroplate diamond wire saw with ultrasonic vibration.Experimental results show that,compared with the same experiment condition without ultrasonic vibration,this cutting method has the advantages of high material remove rate,good surface quality,little brokenness and so on.展开更多
More than 1 000 tons of saw diamond grits were consumed worldwide in 2007.Even with such a mature industry,there are still major improvements possible in developing new grits.The DiaCan<sup>TM</sup> techno...More than 1 000 tons of saw diamond grits were consumed worldwide in 2007.Even with such a mature industry,there are still major improvements possible in developing new grits.The DiaCan<sup>TM</sup> technology with patterned diamond seeding can boost the production yield of coarse mesh diamonds（e.g. 30/40）.Moreover,the DiaMind crystals formed contain a visible core.This diamond-in-diamond architecture allows self-sharpening during sawing application.Furthermore,a revolutionary polycrystalline diamond superabrasive with cubical shape was fabricated to further increase the sawing efficiency and tool longevity.Such DiaCube<sup>TM</sup> polygrits were made tools by brazing them on pearls of wire saws and on the surface of turbo grinders. The pros and cons of major designs of high-pressure equipment for diamond synthesis were discussed with the recommendation to combine the merits of belt apparatus and cubic press.This tooling synergism may increase diamond yield at reduced cost for massive production of saw grits. In 1997 Sung Chien-Min filed a series US patents that described the art of making patterned diamond tools with diamond grits forming an array in three dimensions.He also made the debut of the world’ s first brazing tools with patterned diamond distribution at the stone exhibition in Verona in 1998（also in Nuremberg in 1999）.The patterned diamond saws were introduced by Korean companies in 2005 with the demonstration of increased cutting speeds and prolonged tool lives.展开更多
The cutting process of electroplated diamond wire saw was researched on the basis of impulse and vibration machining theories. The different contact states in the cutting process were analyzed by using the finite elem...The cutting process of electroplated diamond wire saw was researched on the basis of impulse and vibration machining theories. The different contact states in the cutting process were analyzed by using the finite element method. It shows that the cutting stress is uniformly distributed along the direction of the workpiece width in the steady state. A mathematical equation of sawing trajectory was established by using the superposition principle and the cutting experiment of wire saw to calculate the cutting trajectory. The comparison of the theoretical trajectory with the calculated one indicates that the error is less than 15%. The research results provide a theoretic basis for optimization of the saw's cutting process parameters.展开更多
Diamond surface acoustic wave(SAW) has been used to boost the frequency of thin film filters made of piezoelectric materials.Many designs have been tested and with significant results,in particular,AlN on diamond(AlNo...Diamond surface acoustic wave(SAW) has been used to boost the frequency of thin film filters made of piezoelectric materials.Many designs have been tested and with significant results,in particular,AlN on diamond(AlNoD) as the interface for transmitting Rayleigh wave was studied extensively .However,in all cases,nano crystalline or microcrystalline AlN coatings were deposited,typically by sputtering or CVD,on polycrystalline diamond film.The diamond film itself may contain nano or micro grains that are deposited by CVD.The presence of extensive grain boundaries in AlN can attenuate rapidly the propagation of Rayleigh wave.Moreover,the bonding between loose atomic packing of AlN and tight lattice of diamond is weak so much of the mechanical energy is dissipated as heat.In fact,the energy loss is much higher than energy transmitted during the resonating process.In this research,we attempted to improve the matching of atoms at the interface of AlNoD by doping AlN lattice with boron atoms.The shrinking of the lattice may allow more atoms are aligned at the interface.Moreover,a method of coupling single crystal AlN on single crystal diamond is proposed.Such a coupling can maximize the signal-to-noise ratio of the resonating AlNoD at the same time minimize the insertion loss of the SAW filter.展开更多
文摘With the developing of stone material, diamond saw pl ate is used widely, and in order to increase cutting efficiency and life-span o f diamond saw plate, there are a lot of research jobs of segment for diamond saw plate. Layered segment for diamond saw plate is to divide single segment into s everal cutting tools by its structure, then increases rock-cutting faces. For i mpregnated man-made diamond saw plate, the bonding strength of diamonds with ma trix material has great effect on its life and service. Diamond is a kind of non metal and there is such high interface energy between diamond and common metals or alloys that diamond surface can’t be soaked by low melt-point metal or allo y. Diamonds are hold in metal matrix of working layer only mechanically, rather than bonded chemically, so the usage rate of diamonds in working layer is very l ow. Weakly impregnated method refers to covering diamonds with a thin layer of tu ngsten carbide mechanically by physical method, and chemical plating membrane re fers to coating a layer of carbide, which can react with the carbon atoms on the surface of diamond by chemical method and be soaked by matrix metal. In this pa per it analyses working mechanism and sintering process of layered segment of di amond saw plate by means of resistor hot-pressing sintering, it points out shor tages of layered structure, and raises using weakly impregnated layer instead of pure matrix layer, then overcomes the pure matrix layer slipping by pulling out diamonds earlier to improve cutting efficiency of saw plate, in the same time u ses diamond grains of chemical plating membrane proposed then preventing the hea t-hurting to diamond grains in working layer during the process of welding and sintering and improving the bonding strength of diamond with matrix, then improv ing life-span and aging of diamond saw. The theory of the design of mixed holding of diamonds by matrix of saw plate assures that chemical plating diamonds in working layer cut rock and weakly impr egnated diamonds in weakly impregnated layer make segment expose, then design a new type of layered segment for diamond saw plate.
文摘The FEM analysis of stress and deformation of steel base of the special diamond saw blades are carried out.The small carbide round segments are welded on the side of blades in order to increase the side wear re sistance of blade.Comparing with conventional saw blade,the maximum stress val ues of reasonable special saw blade are reduced respectively about 17%20% 33%,and the maximum deformation values are reduced respectively about 26%22 %44.7%in thetangential(X),radial(Y)and axial(Z)direction.The stress conce ntration zone is decreased for the special structure diamond saw blade.The stru ctures of diamond saw blade with different number of hard material pellet are an alyzed and optimized.
基金ProjectsupportedbytheNationalNaturalScienceFoundationofChina (NSFC ) (No .5 0 1 75 0 3 0 ) ,theEducationDepartmentofFujianProvinceinChina (No .JA0 0 2 3 6) ,andtheNaturalScienceFoundationofFujianProvinceinChina (No .F0 1 1 0 0 0 2 )
文摘An experimental study was carried out to quantitati ve ly evaluate the loads acting on the diamond grits during circular sawing of two kinds of typical granite with diamond segmented saw blade. Measurements were mad e of the horizontal and vertical force components and the consumed power in order to obtain the tangential and the normal force components. The temperatures at the diamond-granite contact zone were measured using a foil thermocouple. T he measurement, together with the net sawing power, was subsequently used to est imate the energy partition to the granite by a temperature matching technique. B ased on the energy partition values, the temperatures at individual cutting poin ts were estimated using an analytical model. SEM was used to follow the topograp hies of worn diamond segments. The average force acting on each diamond grit was found to be only 4% of the diamond compressive strength measured by a static me thod. The strength disparity of diamond grits and the random protrusion of grits beyond bond matrix should be significant factors in accounting for the wear of diamond grits. The wear of diamond grits was also found to be closely related to the high temperatures generated at individual cutting points and the pop-outs of diamonds from the bond matrix might be mainly attributed to the heat conducte d to the segments.
基金Project(50675190) supported by the National Natural Science Foundation of China
文摘The heated test pieces were treated with alternating magnetic field by self-made experimental facility firstly. And influences of magnetic treatment on microstructure densification of Diamond Saw Segments were studied through hardness testing, ultrasonic testing, metallurgical structure and fracture pattern analysis by comparative method. The mechanism of magnetic treatment is analyzed and discussed in the end. The results show that the hardness of test pieces after magnetized are harder than before, that HRB hardness is improved by 3.58 on average. The sound path and amplitude of echo wave both decrease in test pieces after magnetized. The relative pad value of echo wave is regularly related with the microstructure densification, what is profound to further establish the regularity studying the degree of matrices densification using ultrasonic testing. The pores become few and pore shape gradually spheroidizing with the magnetic treatment, and matrices are more homogeneous and compact than the without by metallographic microscope. The degree of matrices densification is further improved after magnetized. The average crystal grain size is finer than the without, and the reason of grain refining is that densification of diamond saw blade improved. Magnetic treatment can act as one kind of effective technique to improve the microstructure densification of diamond saw segments.
基金Sponsored by Liaoning Innovation Team Fundation(2008T164)
文摘Based on impulse and vibration machining theories,a mathematical model of cutting force for the electroplated diamond ultrasonic wire saw was established using superposition principle.The differences between the cutting forces with and without ultrasonic effect were analyzed theoretically and experimentally.The results indicate that the cutting force of diamond wire increases along with the spindle speed decrease and the lateral pressure increase.The force in ultrasonic vibration cutting is about 20% to 30% less than that in conventional cutting.Also,the cutting trajectory of single diamond grit in sawing process is simulated,and the reason that the ultrasonic vibration can reduce the cutting force is explained further.
文摘The diamond wire-sawing process was developed to cut granite in both quarries and block processing plants.In this paper,swarf was collected from different areas along the sawing arc when sawing three granites.The particle size distribution and the morphology of the swarf were investigated systematically,along with the swarf formation mechanism in sawing.Granite swarf formation was dominated by transgranular fractures based on the morphology of sawn granite chips and the analysis of sawn chip size.A long cutting arc increased the movement among the swarf,tool,and workpiece,thereby inducing a secondary fracture in the sawn chip.
文摘Diamond grits are indispensable for sawing granite or concrete.Each year about 1 000 tons of diamond grits are consumed for such purposes.In all cases,mono crystalline diamond is used.However, polycrystalline grits(polygrits) are generally better performed than mono grits as abrasives.For example,poly grits of cubic boron nitride(e.g.Borazon(?) CBN-550 of Diamond Innovations) can cut faster and they last longer than mono grits(e.g.Borazon(?) CBN-500). Polygrits of alumina(e.g.Cubitron(?) of 3M) also out perform by far glassy grits(e.g.white alumina).For diamond superabrasives,micron polygrits formed by shock waves may polish as fast as mono grits of the same size,but without causing as much scratches due to the presence of smaller sintered grains.The improved performance of poly grits is attributed to their ability to micro chipping that renews the sharp cutting corners from time to time.By contrast,mono grits tend to round off at low cutting force or macro fracture at high cutting force,so they may lose the cutting ability rapidly. For sawing granite with mesh sizes 40/50 or coarser,poly grits of diamond have not been available until recently.In this research,we have made polygrits in mini cube with sizes of 18/20,20/25,and 30/40.Turbo grinders and wire saws were made by brazing both mono grits and polygrits on steel substrates.Cutting performance on granite demonstrated that grinding speed was faster with turbo grinder,and the surface finish was smoother with wire saw for poly grits than mono ones. Polygrits and mono grits of diamond were mixed for comparison(upper left).Polygrits of mini cubes were brazed on the pearl of a wire saw(upper right).Mono diamond grits were brazed on a turbo grinder(bottom diagrams ).
文摘Four wear modes and four wear mechanisms of diamonds in sawblades are identified in a study of varied segments damaged in field operation of sawing hard stone. The four wear mechanisms are impactshearing, fatiguing, pullingout and thermal effects. Surface erosion is the result of thermal effects, while impactshearing and fatiguing lead to macro and microfracture, and pullingout results in wholesale dislodgement of diamonds provided the inequality Fn>M/(μλδ) is satisfied.
基金Sponsored by Department of Education University Research Project of Liaoning Province(LN566)
文摘The influence of different technological parameter on material remove rate and surface quality of ZrO2 ceramics is studied using the cutting machining method of electroplate diamond wire saw with ultrasonic vibration.Experimental results show that,compared with the same experiment condition without ultrasonic vibration,this cutting method has the advantages of high material remove rate,good surface quality,little brokenness and so on.
文摘More than 1 000 tons of saw diamond grits were consumed worldwide in 2007.Even with such a mature industry,there are still major improvements possible in developing new grits.The DiaCan<sup>TM</sup> technology with patterned diamond seeding can boost the production yield of coarse mesh diamonds（e.g. 30/40）.Moreover,the DiaMind crystals formed contain a visible core.This diamond-in-diamond architecture allows self-sharpening during sawing application.Furthermore,a revolutionary polycrystalline diamond superabrasive with cubical shape was fabricated to further increase the sawing efficiency and tool longevity.Such DiaCube<sup>TM</sup> polygrits were made tools by brazing them on pearls of wire saws and on the surface of turbo grinders. The pros and cons of major designs of high-pressure equipment for diamond synthesis were discussed with the recommendation to combine the merits of belt apparatus and cubic press.This tooling synergism may increase diamond yield at reduced cost for massive production of saw grits. In 1997 Sung Chien-Min filed a series US patents that described the art of making patterned diamond tools with diamond grits forming an array in three dimensions.He also made the debut of the world’ s first brazing tools with patterned diamond distribution at the stone exhibition in Verona in 1998（also in Nuremberg in 1999）.The patterned diamond saws were introduced by Korean companies in 2005 with the demonstration of increased cutting speeds and prolonged tool lives.
基金Sponsored by Innovation team item fund of Liaoning Province ( 2008T164)
文摘The cutting process of electroplated diamond wire saw was researched on the basis of impulse and vibration machining theories. The different contact states in the cutting process were analyzed by using the finite element method. It shows that the cutting stress is uniformly distributed along the direction of the workpiece width in the steady state. A mathematical equation of sawing trajectory was established by using the superposition principle and the cutting experiment of wire saw to calculate the cutting trajectory. The comparison of the theoretical trajectory with the calculated one indicates that the error is less than 15%. The research results provide a theoretic basis for optimization of the saw's cutting process parameters.
文摘Diamond surface acoustic wave(SAW) has been used to boost the frequency of thin film filters made of piezoelectric materials.Many designs have been tested and with significant results,in particular,AlN on diamond(AlNoD) as the interface for transmitting Rayleigh wave was studied extensively .However,in all cases,nano crystalline or microcrystalline AlN coatings were deposited,typically by sputtering or CVD,on polycrystalline diamond film.The diamond film itself may contain nano or micro grains that are deposited by CVD.The presence of extensive grain boundaries in AlN can attenuate rapidly the propagation of Rayleigh wave.Moreover,the bonding between loose atomic packing of AlN and tight lattice of diamond is weak so much of the mechanical energy is dissipated as heat.In fact,the energy loss is much higher than energy transmitted during the resonating process.In this research,we attempted to improve the matching of atoms at the interface of AlNoD by doping AlN lattice with boron atoms.The shrinking of the lattice may allow more atoms are aligned at the interface.Moreover,a method of coupling single crystal AlN on single crystal diamond is proposed.Such a coupling can maximize the signal-to-noise ratio of the resonating AlNoD at the same time minimize the insertion loss of the SAW filter.
