Advantages of orderly arrangement of diamonds
In conventional diamond saw blades, diamonds are randomly and disorderly arranged in the metal matrix, so diamonds are prone to segregation and aggregation in the diamond segments. In the diamond-enriched area, the diamond concentration is high, the single diamond sawing force is small, and it is easy to be polished and worn, and it is easy to block and hinder the removal of cuttings, resulting in a decrease in sawing efficiency. In the diamond sparse area, due to the excessive workload and high impact force of a single diamond, the diamond is easy to break and fall off. Therefore, the saw blade with disordered arrangement of diamonds has the problems of low sawing efficiency, short tool life and contradictory sawing efficiency and life.
In recent years, in the diamond tool industry, the design and process of the orderly arrangement of the diamond segments diamonds have been introduced, which can evenly arrange the diamonds with the optimal spacing in the production of the diamond segments. The experimental data show that the orderly arrangement can improve the sharpness and life of the diamond saw blade at the same time, and reduce the diamond concentration and save the cost.
The performance of a diamond tool depends on a number of factors, the characteristics of the diamond being used i.e. the size, strength and structure of the diamond is one of the most critical factors. The life, power consumption and sawing efficiency of diamond tools ultimately depend on the combined action of all diamonds on the tool surface (in the diamond segments), including the particle size, concentration of diamonds in the diamond segments, diamond protrusion height, distance between diamonds and its arrangement, etc. The relationship between diamond uniform distribution and ordered arrangement and other parameters and its influence on the performance of diamond tools.
When the diamonds are randomly distributed and disordered, the diamonds are too dense at a, and the diamond spacing is too small. The diamond is mainly in the grinding and polishing stage, the cutting force of each diamond is small, the sawing life is long, and the sawing efficiency (speed) is low. When the diamond segregates at c, the diamond spacing is too large, each diamond bears a large load, the cutting force is large, the slag discharge gap is smooth, the sawing efficiency is high, and the speed is fast. However, diamond is easy to dry off and chip, the matrix wears quickly, and the service life is short.
When the diamonds are evenly distributed and arranged in an orderly manner, the diamond spacing can be optimized according to the different sawing objects and sawing conditions. At this time, the diamonds can be effectively used, play the role of cutting, and can fully remove chips and flush cooling, which can achieve both The optimization purpose of improving sawing efficiency and improving saw blade life.
The cutting efficiency of diamond on the saw blade surface depends on the distribution of diamond spacing and the wear condition of individual diamonds. The research shows that the average diamond spacing of the matrix diamond blades is 4mm, the diamond is 40/50 mesh, and the concentration is 11ct/cm. After sawing, the spacing of 85% diamonds in the matrix diamond blades is 27mm, while the ordinary saw blades are only 60%. At this time, the sawing time and sawing force of the matrix diamond blades are significantly improved. The increase of diamond content has little effect on the cutting load, but the sawing time is significantly prolonged, resulting in a significant improvement in the life and efficiency of the saw blade.
Crafting of Matrix Diamond Blades
There are mainly the following methods to realize the orderly arrangement of diamonds in the diamond segments.
The first step of the method: Mix the matrix powder evenly, add appropriate organic binders and solvents, etc., and make a thin layer 100 by rolling method. According to the distribution and arrangement of diamonds, a template 110 is made, and its aperture 114 must be large. The size of a single diamond is smaller than the size of two diamonds, ensuring that one diamond enters the die hole, and the thickness of the template is 1/3~2/3 of the average diamond particle size. The second step: the diamond 20 is distributed on the template, and the diamond is pressed into the matrix through the hole 114 of the template 110 with a steel flat plate 120. The third step: remove the excess diamond on the template, remove the template, and press the diamond into the thin layer 100 of the matrix with a steel flat plate. Step 4: Repeat the above steps and methods to press the diamond into the other side. Then, the diamond segments is assembled with multi-layered diamond thin layers, and then sintered in a graphite mold to form the diamond segments. This method can accurately distribute and arrange the diamonds evenly as required, but the efficiency is low and manual operation is required, so mass production and industrialization are difficult.
The device of the dispensing method consists of a glue reservoir and a micro-metering diamond segments. The micro-metering diamond segments consists of a piezoelectric driver, a thermistor, a heating coil and a power supply, as well as a metering control device. The glue is fed from the glue storage tank to the micrometer through the feeding tube. When a voltage pulse is applied, the piezoelectric actuator will shrink, thereby discharging a glue drop. The maximum discharge frequency is 2000Hz, and the maximum nozzle diameter is 40um. The device can measure and batch the glue with higher viscosity. According to the position of the workpiece and the movement of the glue dispenser, the glue can be evenly arranged on the workpiece, and then the diamonds are spread on the glue droplets to form a uniform arrangement of the diamonds.
ARIX Auto Layout System
The ARIX automatic arrangement system was developed by a Korean company. Since 2001, the company has been able to successfully arrange diamonds in the diamond segments evenly and orderly by June 2003, but the production efficiency cannot meet the requirements. After a year of intensive efforts, in December 2004 announced the completion of the ARIX automatic arrangement system, which can 100% control the spacing of the inner diamonds in the diamond segments, and can automatically produce 50,000 diamond segmentss per month. Now our company has also mastered this technology. With the progress of the diamond tool industry, the advantages of orderly arrangement of diamonds in the diamond segments have been recognized by people, and some process technologies of orderly arrangement have also appeared, but most of them have low production efficiency and are not suitable for mass production. Therefore, how to realize the industrialization of the orderly arrangement of diamonds in the diamond segments is the focus of research.