Fixing method of diamond wire saw beads for cutting stone
The diamond wire saw bead fixing technology includes spring fixing method, plastic or rubber injection molding method and spring injection molding method combined with the two.
The spring fixing method is adopted, that is, the beads are fixed on the wire rope through springs and washers. The biggest disadvantage of this fixing method is the lack of protection of the wire rope. The coolant directly corrodes the wire, and the rock debris enters the spring or even the beaded matrix, which will directly wear the wire rope, greatly shorten the life of the wire rope, and easily lead to the breakage of the saw wire. . Therefore, the spring fixing method is mostly used to fix the electroplated beads with short life, and it is used in open mines to avoid casualties caused by the rupture of the beaded rope.
Plastic or rubber injection molding
Plastic or rubber injection molding is the most common method of securing beaded rope. After casting, the entire beaded rope is completely covered by plastic or rubber, including the gap between the inner hole of the beaded bead and the wire rope, which is filled with casting material, so that the wire rope is well protected from being corroded by coolant and by cuttings. Abrasion increases the service life of the wire rope. In addition, each bead is cast and connected to the wire rope. Even if the wire rope breaks, the bead is not easy to fly out at a high speed and cause an accident. Therefore, it can be used for indoor processing and demolition of buildings in public places. To match this, most of the beads are sintered beads with longer service life.
Spring injection method
Fix with springs, then cast plastic. This method has better use effect, but the manufacturing process is more complicated and the cost is correspondingly increased.
Structure of the steel matrix of the wire saw
Under normal circumstances, plastic and steel materials cannot be bonded together. In order to fix the beads and prevent them from producing axial displacement and rotating around the wire rope, the steel base is designed as a mechanical clamping structure. In the design of this clip-inlay structure, in addition to ensuring sufficient clip-inlay strength, the appropriate clearance between the bead and the wire rope must also be considered. In order to ensure the concentricity of the beads and the wire rope during the injection molding process, otherwise the wire saw will be eccentric in use, which will seriously affect the use of the wire saw.
Plastic (rubber) fixing structure
An important role of the plastic (rubber) fixed structure is to contain chips, store water, slow down the impact and protect the wire rope. There are two main types of plastic fixed structural forms: one is a wrapping structure, that is, the exposed substrate is completely wrapped, and the other is a straight structure with the substrate. There are several other forms of wrapped structure, such as platform type, inclined surface type and platform plus inclined surface or groove type (inner diameter positioning). In order to ensure the concentricity of the beads and the wire rope, the outer diameter of the beads is mainly used for the positioning of the outer diameter of the beads in the wrap-type injection molding, and the outer diameter of the base is used for the flat type. The test results of several fixed structure forms show that the wrapped structure has the advantages of good waterproof performance and tighter wrapping, and the inclined surface also has a certain effect of reducing impact, but the two have a greater effect on chip removal space and chip removal. Especially in the later period of use of the wire saw, when the steps are close to the working level, due to the small space for chip removal, the frictional resistance increases, and the cutting efficiency will decrease (about 10%~20%); the straight fixed structure has a structure Simple, accurate positioning, less difficulty in mold processing, relatively large chip removal space, and high efficiency in wire saw cutting, but the waterproof protection of wire rope is significantly lower than that of stepped wrapping and fixing. break, thus affecting the use of the wire saw. Generally speaking, for special-shaped processing, a straight type or a small step-wrapped plastic fixed structure can be used, but in the case of harsh working conditions such as mining, or where the coolant is corrosive to the wire rope, it must be used. Step wrapping, and the wrapping thickness is relatively large.
Wire rope in diamond wire saw for cutting stone
During the use of the wire saw, the wire rope often breaks due to fatigue wear, abrasion, chemical corrosion, etc., especially when the area of the cut stone reaches a certain amount, the wire breakage is more frequent. Broken rope not only affects production, but also brings safety hazards such as throwing beads and hurting people. Therefore, the performance of steel wire ropes is very important for the use of beaded ropes. In addition to the performance of the steel wire itself, the life of the steel wire rope is also related to the pre-tightening tension in the processing process, the minimum curvature of each guide wheel, the axial load of the beads during the processing process, and the impact load. Therefore, the products of professional steel wire rope manufacturers should be selected. And use should refer to the relevant instructions of the wire rope.