CN111923262B

CN111923262B - Circular wire saw and manufacturing method thereof

Info

Publication number: CN111923262B
Application number: CN202010991484.6A
Authority: CN
Inventors: 刘瑞山
Original assignee: Tianjin Nickel Armor Surface Treatment Technology Co ltd
Current assignee: Tianjin Nickel Armor Surface Treatment Technology Co ltd
Priority date: 2020-09-21
Filing date: 2020-09-21
Publication date: 2021-01-08
Anticipated expiration: 2040-09-21
Also published as: CN111923262A

Abstract

An endless wire saw and a method of manufacturing the same, the endless wire saw comprising an endless substrate formed of a core wire layer and a strand layer, wherein: the core wire layer is an annular structure formed by winding at least two circles of single core wires along a loop wire direction and connecting the core wires end to end; and a strand layer having a helical structure formed by sparsely winding a single strand around the core layer at predetermined intervals. The invention changes the structure and function of the traditional compound yarn and core yarn, leads the compound yarn to be spirally protruded on the surface of the core yarn, and solves the problems of low production efficiency, low tensile strength of a matrix and high shedding rate of abrasive particles caused by the complex manufacturing process of the existing annular wire saw.

Description

Circular wire saw and manufacturing method thereof

Technical Field

The invention relates to the technical field of cutting, in particular to an annular wire saw and a manufacturing method thereof.

Background

The rare earth permanent magnet, silicon materials, sapphire, ceramics, stones and other brittle and hard materials have high hardness and large brittleness, and are easy to break and damage in the cutting process, so that the materials are damaged, and the yield is reduced, so that the materials are difficult to cut by adopting a common processing method. The traditional cutting of these brittle and hard materials usually adopts diamond inner circle and outer circle cutting technology and diamond band saw. However, as the semiconductor industry develops, the diameter of monocrystalline silicon ingots is larger and larger, now reaching 450 mm, and that of polycrystalline silicon ingots is 800 mm. At present, band saws are mainly adopted for cutting off and squaring, the cutting efficiency is high, but the cutting seam is wide, and the cutting surface is not flat. In addition, the traditional material cutting industry is concerned with the effective utilization rate of raw materials. In view of these problems, diamond wire saws have been produced, and this technique is to bond diamond to the surface of a steel wire by means of resin, electrodeposition, punching, or the like. However, the existing diamond wire saw has the problems of wide cutting seam, low cutting efficiency, poor cutting surface quality, high falling rate of superhard abrasive particles, pending improvement of tensile strength of the wire saw and the like, which affect the service life.

Disclosure of Invention

In view of the above, the present invention is directed to a ring wire saw and a method for manufacturing the same, which is designed to solve at least one of the above-mentioned problems.

In order to achieve the purpose, the technical scheme of the invention is as follows:

as one aspect of the present invention, there is provided an endless wire saw comprising an endless substrate formed of a core wire layer and a strand layer, wherein: the core wire layer is an annular structure formed by winding at least two circles of single core wires along a loop wire direction and connecting the core wires end to end; and a strand layer having a helical structure formed by sparsely winding a single strand around the core layer at predetermined intervals.

As another aspect of the present invention, there is provided a method of manufacturing the above ring wire saw, including: winding at least two circles of single core wires along a loop wire direction, and connecting the two circles of single core wires end to form a core wire layer with an annular structure; and sparsely winding single strands on the core wire layer at predetermined intervals to form a strand layer with a spiral structure.

According to the technical scheme, the ring wire saw and the manufacturing method thereof have at least one or part of the following beneficial effects:

(1) the core wire layer adopts a structure that a single core wire is wound in multiple circles, namely the cross section of the core wire layer is provided with a plurality of core wires which are connected in series, so that the core wire layer plays a role of bearing external load, the single core wire is wound sparsely outside the core wire layer to form a spiral structure of the core wire layer, so that the plurality of core wires can be attached and fixed to form a stable annular structure, the convex surface is provided to facilitate consolidation of abrasive particles, the falling of the abrasive particles in the using process is reduced, the special structure of the core wire layer and the strand wire layer can obviously improve the tensile strength of the annular wire saw, reduce the falling of the abrasive particles and prolong the service life.

(2) The annular wire saw provided by the invention mainly bears external load by the core wire layer, and compared with the core wire structure which is stranded mutually, the multi-turn winding structure of the core wire layer has the advantages that the torsional stress is very small, the rigidity of the core wire is not damaged, and the multi-turn winding structure is a key factor capable of bearing external large load, so that the diameter of an annular substrate formed by the core wire layer and the strand wire layer is reduced on the whole under the condition of ensuring the tensile strength of the annular wire saw, and the annular wire saw has the advantages of narrower cutting seam and better cutting surface quality.

(3) The annular wire saw has the advantages that the core wire layer is wound by adopting a single core wire along the annular wire direction, the winding mode is simple, the strand layer is wound by adopting a single strand sparsely, the winding lay length is flexible to select, and compared with the existing mode of winding the strand closely on the core wire, the manufacturing process is simpler, the industrial production is favorably realized, and the production efficiency is improved.

Drawings

FIG. 1 is a schematic structural view of a ring wire saw according to an embodiment of the present invention;

FIG. 2 is a schematic structural view of a core wire wound two turns in accordance with an embodiment of the present invention;

FIG. 3 is a schematic front view of an annular substrate according to an embodiment of the present invention;

FIG. 4 is a schematic side view of an annular substrate according to an embodiment of the present invention.

In the above figures, the reference numerals have the following meanings:

100 an annular base; 110 a core wire layer; 120 strand layers;

200 abrasive layers; 210 abrasive particles; 220 metal coating.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to specific embodiments and the accompanying drawings.

In the process of implementing the present invention, it is found that the existing ring wire saw generally adopts a 1 × 7 steel strand structure, that is, a plurality of strands are tightly wound outside one core wire, the core wire only provides a supporting function, and the strands are used as a main part for bearing an external load, because there is a requirement for plasticity of the strands, the strands and the core wire generally adopt steel wires with different rigidities, the rigidity of the strands is weaker than that of the core wire, and even if materials with the same rigidity are adopted, the rigidity of the steel wires can be damaged due to the action of torsional stress after the strands are wound, so that the overall tensile strength of the ring wire saw is not high. Therefore, the invention provides a novel ring-shaped wire saw, which changes the structure and the function of the traditional wire saw, is easy to manufacture and can realize mechanical production in the future.

According to some embodiments of the present invention, a ring wire saw is provided, and fig. 1 is a schematic structural view of a ring wire saw according to an embodiment of the present invention. As shown in fig. 1, the ring wire saw of the present invention comprises: an annular substrate 100 formed of a core layer 110 and a strand layer 120, wherein: the core wire layer 110 is an annular structure formed by winding at least two turns of a single core wire along a loop wire direction and connecting the two turns of the single core wire end to end; and a strand layer 120 having a helical structure in which individual strands are sparsely wound around the core layer 110 at predetermined intervals.

For convenience of explaining the winding structure of the core wire layer 110, taking a single core wire wound by two turns as an example, fig. 2 is a schematic structural diagram of the core wire wound by two turns according to the embodiment of the present invention, it can be seen that two core wires connected in series are provided in the same cross section, it should be understood that the winding gap between the core wires shown in the figure is only for clearly illustrating the winding structure of the single core wire, and a plurality of series core wires located in one section in the core wire layer formed by actual winding are actually tightly attached to each other, so that the winding is performed along a loop wire direction, thereby providing higher tensile strength on the whole and prolonging the service life.

A single heart yearn can also twine and be greater than two circles and form annular structure, along with the increase of single heart yearn winding number of turns, the tensile strength on heart yearn layer also improves thereupon, nevertheless if the winding number of turns is too much then can lead to the heart yearn layer too thick to increased the kerf width when cutting such as semiconductor material, be unfavorable for cutting surfacing, therefore the winding number of turns of single heart yearn in the heart yearn layer is preferred 3~50 circles, be 3, 4, 5, 6, 7, 8, 10 the number of turns for example.

As shown in fig. 2, the individual cords are wound in a plurality of turns and then joined end to end, it being understood that the end to end connection may be achieved in a variety of ways, such as welding, bonding, etc.

When the individual strands are wound along a predetermined interval, the predetermined interval refers to an interval between two adjacent strands on the core layer. In some embodiments, the strand layer 120 is preferably formed by winding a single strand around the core layer 110 with equal pitch, and the individual strands are connected end to end, and such equal pitch winding can reduce the possibility of uneven distribution of breaking strength, thereby improving the reliability of the circular wire saw. In some embodiments, the strand preferably has a winding lay length of 1 to 15 times, more preferably 2 to 10 times the diameter of the strand. The selection of the lay length has certain relevance according to the winding number of the core wire, and the specific lay length can better control the abrasive particles to be evenly distributed and solidified on the surface of the core wire under the condition of ensuring the core wire to be tightly bundled, so that the smoothness of the cut surface is improved.

In some embodiments, the number of winding turns of a single strand in the loop direction is at least one, and is not particularly limited as long as a predetermined interval can be formed between adjacent strands on the core layer, so as to achieve sparse winding and end-to-end connection, and it should be noted that, in this case, the core layer is taken as an axis, a point is selected on the core layer, and the winding of the strand starts in a spiral manner until the point is wound again, and the point is counted as one turn.

Although not shown in the drawings, the end-to-end connection structure of the strands is similar to the end-to-end connection of the core wires, and may adopt a twisting manner, and other manners such as welding and bonding, which are not described herein again. Preferably, the joints of the strands and the joints of the core wire are not located at the same position, and more preferably, they are located at opposite ends of the loop wire, respectively, so that the points at which the ring wire saw is susceptible to breakage are not located at the same position, thereby improving the reliability of the ring substrate 100.

The helical structure of strand layer 120 is owing to be the protruding structure on protrusion in heart yearn layer surface, and this kind of helical structure can play the protection abrasive grain on the one hand when the cutting uses, reduces the effect of abrasive grain's the rate of coming off to increase of service life, on the other hand still is favorable to taking the smear metal that the cutting produced out, improves cutting efficiency.

Fig. 3 and 4 show the structure of an annular substrate 100 formed by a core wire layer 110 and a strand layer 120, where fig. 3 is a schematic front structure of an annular substrate according to an embodiment of the present invention, fig. 4 is a schematic side structure of an annular substrate 100 according to an embodiment of the present invention, and it can be seen that a cross section of the core wire layer 110 of the annular substrate 100 shown in the figure has seven core wires connected in series, that is, a single core wire is wound by seven turns, and the strand layer 120 is wound on the surface of the core wire layer 110, so that the core wire layer 110 is attached to form a stable annular structure.

In some embodiments, the core wire and the strand may be made of metal filament or nonmetal filament, such as steel wire, etc., or nonmetal filament, such as carbon fiber, nylon, cotton fiber or glass, etc., which are commonly used in the prior art, and are selected according to the actual cutting requirements. The diameter of annular base member 100 is 0.2 mm ~5 mm, and the diameter of heart yearn is 0.01mm ~1mm, and the diameter of strand is 0.01mm ~1mm, specifically selects according to the material and the practical application demand of selecting for use, understands easily, if the diameter is thin then be difficult to guarantee annular coping saw's rigidity or tensile strength, if thick then can lead to being difficult to twine, or lead to the cutting seam too wide.

With continued reference to fig. 1, the present invention further includes an abrasive layer 200 comprising abrasive particles 210 formed on the surface of the annular substrate 100.

In some embodiments, the abrasive particles 210 are ultra-hard abrasive materials, which may be conventional in the art, such as diamond, cubic boron nitride, and B₆O or a combination of any two or more of O. In some embodiments, abrasive layer 200 includes, in addition to abrasive particles 210, a metal coating 220 for encasing the abrasive particles, where metal coating 220 includes one or a combination of two or more of gold, silver, nickel, zinc, lead, copper, tin, titanium, tantalum, chromium, or zirconium. In some embodiments, the abrasive particles 210 have a particle size of 2 μm to 500 μm, and the metal coating 220 has a thickness of 1 μm to 200 μm, which can be selected according to actual requirements and selected materials.

On the basis, the abrasive layer 200 containing the abrasive particles 210 and the metal coating 220 is preferably fixed on the surface of the annular base 100 in an electro-deposition mode, the abrasive layer 200 is easily fixed on the surface of the annular base 100 due to the convex structure of the surface of the annular base 100, and the abrasive particles 210 can be distributed on the metal coating more uniformly.

Preferably, the abrasive particles distributed on the surface of the metal coating 220 are embedded in the metal coating 220 to a depth of 1/3-2/3 of the particle size of the abrasive particles, so that the abrasive particles can be prevented from falling off while providing a rough surface for cutting, and the service life of the abrasive particles is prolonged.

In other embodiments, metal coating 220 may be replaced with a material such as a resin, which causes abrasive particles 210 to adhere to the surface of the annular substrate with less strength or abrasion resistance than metal coating 220, and abrasive layer 200 may be formed by, for example, but not limited to, coating and curing.

As shown in FIG. 1, the abrasive layer 200 is continuously disposed on the annular substrate 100, and in other embodiments, may be intermittently disposed on the annular substrate 100, such that the intermittent configuration is more conducive to carrying away swarf during cutting operations.

There is also provided, in accordance with some embodiments of the present invention, a method of making the above-described ring wire saw, including:

step 1: the single core wire is wound at least two turns along a loop direction and connected end to form a core wire layer 110 of a ring structure. In this step, a core wire with a suitable length is selected according to the size of the required annular structure and the number of winding turns, and the specific winding manner is as described above and will not be described herein.

Step 2: the individual strands are sparsely wound around the core wire layer 110 at predetermined intervals to form a strand layer 120 of a helical structure. In this step, a strand with a suitable length is selected according to the cross-sectional size and the circumference of the core wire layer 110 and the required winding lay length, and the specific winding manner is as described above and will not be described herein.

Further, the manufacturing method also comprises the step 3: an abrasive layer 200 containing abrasive particles 210 is formed on the surface of the annular substrate 100 formed by the core wire layer 110 and the strand layer 120. The abrasive layer 200 is formed as described above and will not be described herein.

So far, the embodiments of the present invention have been described in detail with reference to the accompanying drawings. It is to be noted that, in the attached drawings or in the description, the implementation modes not shown or described are all the modes known by the ordinary skilled person in the field of technology, and are not described in detail. Further, the above definitions of the various elements and methods are not limited to the various specific structures, shapes or arrangements of parts mentioned in the examples, which may be easily modified or substituted by those of ordinary skill in the art.

In conclusion, the invention provides the annular wire saw and the manufacturing method thereof, which change the structure of the traditional wire saw, increase the number of core wires, change the structure and the function of the traditional compound wire, ensure that the compound wire protrudes out of the surface of the core wire in a spiral shape, have simpler structure, high tensile strength and easy manufacture, can realize mechanical production in the future, and solve the problems of low production efficiency, low substrate tensile strength and high abrasive particle falling rate caused by the complex manufacturing process of the existing annular wire saw.

The above-mentioned embodiments are intended to illustrate the objects, technical solutions and advantages of the present invention in further detail, and it should be understood that the above-mentioned embodiments are only exemplary embodiments of the present invention and are not intended to limit the present invention, and any modifications, equivalents, improvements and the like made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. An endless wire saw comprising an endless substrate formed of a core wire layer and a strand layer, wherein:

the core wire layer is an annular structure formed by winding at least two circles of single core wires in an untwisted mode along an annular wire direction and connecting the two circles of single core wires end to end; and

the strand layer is a spiral structure formed by sparsely winding single strands on the core layer at predetermined intervals.

2. The ring jigsaw of claim 1, wherein the single core wire is wound from 3 to 50 turns.

3. The endless wire saw of claim 1, wherein said single strand is wound around said core wire layer at equal lay lengths and end-to-end; the number of winding turns of the single strand in the loop direction is at least one.

4. The endless wire saw of claim 3, wherein the splices of the strands are not co-located with the splices of the core wire;

the winding lay length of the folded yarn is 1-15 times of the diameter of the folded yarn.

5. The endless wire saw according to claim 1, wherein the annular base has a diameter of 0.2 mm to 5 mm, the core wire has a diameter of 0.01mm to 1mm, and the strand has a diameter of 0.01mm to 1 mm.

6. The ring wire saw of claim 1, further comprising an abrasive layer containing abrasive particles formed on the surface of the annular substrate, wherein the abrasive layer is continuously or intermittently distributed along the extension direction of the annular substrate.

7. The ring wire saw of claim 6, wherein the abrasive particles are diamond, cubic boron nitride and B₆One or a combination of any two or more of O;

the abrasive layer further comprises a metal coating for wrapping the abrasive particles, wherein the metal coating comprises one or more of gold, silver, nickel, zinc, lead, copper, tin, titanium, tantalum, chromium or zirconium.

8. The annular wire saw of claim 7, wherein the abrasive particles have a particle size of 2 μm to 500 μm, and the metal coating has a thickness of 1 μm to 200 μm;

and the depth of the abrasive particles distributed on the surface of the metal coating embedded into the metal coating is 1/3-2/3 of the particle size of the abrasive particles.

9. A method of making the ring wire saw of any one of claims 1-8, comprising:

winding at least two circles of single core wires along a loop wire direction, and connecting the two circles of single core wires end to form a core wire layer with an annular structure;

and sparsely winding single strands on the core wire layer at predetermined intervals to form a strand layer with a spiral structure.

10. The method of manufacturing of claim 9, further comprising: an abrasive layer containing abrasive particles is formed on the surface of the annular matrix formed by the core and strand layers.