Measurement And Simulation Calculation of Wire Bow Angle During The Diamond Wire Saw Process

The wire bow angle is an important factor that affects the shape precision of an ingot after the diamond wire sawing process. In this research, the wire bow angles of the inside and outside of an ingot were recorded with a high-speed camera. The effects of the processing parameters such as the wire tension force, feed speed, and wire speed on the wire bow angles inside and outside the ingot were analyzed. A numerical simulation model of the wire bow in the wire sawing process is presented in this paper to describe the wire bow angle inside the ingot. It was shown that the wire bow angle inside the ingot was smaller than that of outside the ingot for all of the processing parameters. The wire bow angles improved with the increase of the feed speed and decrease of the wire speed and the wire tension force. The results of the wire bow angle measurement of the inside ingot and the simulation calculation were similar for the process parameters.

Experimental Investigations On Optimizing Manufacturing Parameters For Electro-Spark Deposition Diamond Wire Saw

The third generation of superhard semiconductor materials, represented by single-crystal SiC, is used widely in microelectronics due to their excellent physical and mechanical properties. However, their high hardness and brittleness become the bottleneck of their development. Diamond wire saw (DWS) has become the mainstream tool for sawing hard and brittle crystal materials. However, the diamond abrasive is consolidated on the core wire through resin or electroplated nickel, and the holding strength is not high. When sawing superhard crystal materials, the efficiency is low. In order to improve the sawing efficiency of superhard crystal materials, it is of great significance to improve the wear resistance of wire saw and the holding strength of abrasive particles. Electro-spark deposition (ESD) can deposit electrode materials on the substrate with low heat input to achieve metallurgical bonding between metal materials. It can effectively improve the gripping strength of the abrasive grains. And the sawing ability of the wire saw to make the consolidated DWS by the ESD process. In this paper, the ESD equipment has been designed according to the characteristics of the ESDDWS process. The discharge gap size and electrode consumption are monitored in real-time by a single-chip microcomputer (SCM). Orthogonal experiments were carried out for the two motion modes. The effects of process parameters, such as (A) Grain size, (B) Abrasive content, (C) Pulse duration time, (D) Compacting pressure, (E) Current, (F) Electrode diameter, (G) Pulse interval time, (H) Reciprocating times, (I) Wire feed speed, on the quality of ESDDWS were analyzed. Through the extremum difference analysis, the optimal parameter combinations of ESDDWS were obtained. The results of the validation experiment are better than the original experimental results.

Fluid Flow Analysis of Agitation Pipe in the Electroplated Diamond Wire Saw

Agitation pipe is the important part of the electroplated diamond wire saw in the suspension sanding process. The structure type and the sandblasting configuration in agitation pipe play a role on the flow uniformity. Fluid flow in the different structure forms of agitating pipe was studied and the influence of sandblasting angle and the diameter was also contrasted. Results found that the central water type of agitation pipe has the better performance, generating the flow field distribution in the middle part with high velocity and small velocity on both sides. The order of sandblasting in performance was 30°, 45° and 60°. The better flow uniformity occurred in the configuration of sandblasting with the diameter 7.5 mm, 7 mm and 7.5 mm.

Influence of the Agitation Pipe on the Flow Field of Electroplating Tank in the Electroplated Diamond Wire Saw

In order to solve the problem of diamonds sedimentation in electroplating tank and uneven distribution of diamonds in coatings, the fluid flow in the electroplating tank formed by three structure kinds of agitation pipe was compared and analysed. Results showed that the middle inlet type agitation pipe can significantly improve the fluid uniformity in the electroplating tank, and setting sand blasting ports at both ends of the agitation pipe can avoid the formation of fluid “dead zone”. Along the direction of the agitation pipe, the middle inlet type agitation pipe improves the overall flow of the fluid. In the position of the wire saw passing through, the difference of the speed in the electroplating tank of the middle inlet type is 47.17% and 15.25%, which is significantly lower than that of the water inlet structure of one end by 134.48%. As a result, it can significantly improve the plating effect of the wire saw.