Latest developments in diamond wire saws

Abstract: Diamond wire saws have been widely used in stone cutting and construction engineering. Some new processes and new methods have been used to make diamond wire saws. The beaded automatic cold press forming technology and beaded hot isostatic pressing technology have greatly improved the production efficiency and greatly reduced the manufacturing cost. Brazing technology and diamond oriented arrangement technology have improved the overall performance of the diamond wire saw. The use of these technologies to create high-performance small-diameter wire saws and wire ropes for engineering construction further expands the use of wire saws.

1 Introduction

As a flexible and ultra-hard material cutting tool, diamond wire saw has been developed for more than 40 years since its introduction, from the initial electroplating technology to the manufacturing technology with sintering and brazing technology as the mainstream; The quality of stone is widely used in the mining of blocks in granite mines, the cutting of reinforced concrete or metal structural parts, and the application range is also becoming wider and wider while the manufacturing technology is new. At present, the comprehensive performance of domestic diamond wire saws is close to the international advanced level, and the cost is low, which can fully meet the needs of domestic stone mining and sheet metal processing industry. Even many wire saw products produced by enterprises have begun to be exported to western countries such as Europe and America. With the rapid popularization and use of diamond wire saw machinery and diamond wire saw cutting technology, China's stone block material mining has entered the era of diamond wire saw, diamond wire saw manufacturing enterprises have achieved unprecedented development. For example, in 2007, the output of a diamond wire saw in a domestic company reached more than 30,000 meters, the output value was 15 million yuan, and the profit was more than 3 million. Compared with the previous year, the output, output value, profit and other indicators have doubled. Through the independent innovation, the domestic diamond wire saw manufacturing enterprise has promoted the rapid progress of the domestic diamond wire saw technology and laid a solid foundation for the further promotion and use of the diamond wire saw.

2. New process for making diamond wire saw

With the increase in the use of diamond wire saws and the continuous expansion of the application surface, the production technology of diamond wire saws is constantly improving. In order to meet the rapid development of the domestic and international markets and catch up with the international advanced level, some domestic companies have been in recent years. Constantly introducing new equipment, researching and applying new technologies, while the scale of production is expanding, product quality and production efficiency are also greatly improved, while production costs are declining.

2.1 Granulation and volumetric automatic cold pressing process

At present, domestic wire saw manufacturers generally use non-granulated powder for manual cold-pressed bead production, which has low production efficiency, product quality is easily affected by human factors, and the working environment is dusty, which is not conducive to human health.

In view of the many drawbacks of using non-granulated powder for cold pressing, a domestic company first applies the powder granulation process and supporting equipment to production practice. The powder granulation process is to add the powder into the container by the high-speed rotation of the agitator and the cutting knife and spray the atomizing solvent to form the granules. The granulation of 10kg powder can be completed in 20 minutes, and the granulated powder is dried and screened. It is made into spherical particles of 30 to 80 mesh, and the molding ratio is 85% or more. The powder prepared by this method has better fluidity. After the diamond is mixed with the granulated powder, the diamond is more evenly distributed on the working lip surface; the coated diamond surface is wrapped by powder and is avoided during the pressing process. Direct contact with the mold surface reduces the loss of the mold.

After powder granulation technology and diamond coating technology, some domestic companies introduced foreign-made automatic cold presses for bead production. The equipment is based on the volumetric method (the amount of fixed powder) from the loading to the substrate and the carcass. Cold press forming together, high degree of automation, saving manpower, thereby greatly improving production efficiency and reducing production costs.

2.2 Hot isostatic pressing technology

Diamond bead sintering is an important part in the production of wire saws, which directly affects the sawing performance of wire saws. Beading is a thin-walled cylindrical structure, which requires high density of sintering. The usual hot-pressing sintering method is too thin due to the upper and lower indenter walls, and the pressure-reducing ability is poor, which directly limits the sintering density of the bead, and the head loss is large, and the cost is relatively high. high. The traditional method of first cold pressing and no pressure sintering, the density of beading sintering is lower, which seriously affects the performance of the wire saw. At present, the most effective sintering method is to use hot isostatic pressing (HIP) technology. In the bead production, the sintered beads are placed in the glass sleeve (there are also enterprises that do not put glass sleeves and directly put into hot isostatic pressing). In the sintering furnace, placed in a hot isostatic press, using inert gas Ar gas as the pressure transmitting medium, the temperature is raised to 800 ° C ~ 900 ° C for isostatic pressing, and then the glass cover is removed by roller treatment or shot peening . The bead produced by the technology has less pores and high density, can improve the hardness, strength, wear resistance and working life of the bead, and can also improve the bonding strength between the substrate and the carcass; Packing thousands of beads for mass production.

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