CN202640582U - A fixed abrasive sawing wire - Google Patents
A fixed abrasive sawing wire Download PDFInfo
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- CN202640582U CN202640582U CN 201120424277 CN201120424277U CN202640582U CN 202640582 U CN202640582 U CN 202640582U CN 201120424277 CN201120424277 CN 201120424277 CN 201120424277 U CN201120424277 U CN 201120424277U CN 202640582 U CN202640582 U CN 202640582U
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D61/00—Tools for sawing machines or sawing devices; Clamping devices for these tools
- B23D61/18—Sawing tools of special type, e.g. wire saw strands, saw blades or saw wire equipped with diamonds or other abrasive particles in selected individual positions
- B23D61/185—Saw wires; Saw cables; Twisted saw strips
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Abstract
A fixed abrasive sawing wire suitable for sawing hard and brittle materials is disclosed. The sawing wire is of the type wherein hard particles, preferably diamond particles, are pushed into a soft indentation layer that covers a hard steel wire core. After indentation, particles are fixed further by means of a binding layer. The sawing wire is particular in that the indentation layer is build-up out of two metallic layers: a first metal layer closest to the steel wire core on top of which a second metal layer is deposited. The first metal is softer than the second metal. The second metal layer is thin in order not to limit the indentation capability of the first metal layer. It is conjectured that the second metal layer is like a skin that improves the particle retention capabilities of the fixed abrasive sawing wire. Also described are a number of methods to produce such a kind of wire.
Description
Technical field
The utility model relates to the field of fixed-abrasive sawline for the cutting hard brittle material, and more specifically, the utility model relates to abrasive grain wherein and is pressed into and remains on monofilament sawline in the monofilament skin.
Background technology
Current, be used for cutting such as quartzy (being used for for example quartz oscillator or light shield), silicon (being used for for example IC wafer or solar cell), GaAs (being used for high-frequency circuit), carborundum or corundum (for example being used for the blue light diode substrate), magnetic rare earth alloy (for example being used for magnetic recording head) or even the major technique of the hard brittle material of the costliness of natural or the artificial stone high-tension sawline by very thin carbon steel carry out.Although used line is called as " sawline ", its abrasive grain that is mode (being generally the suspension of the silicon-carbide particle in the polyethylene glycol) in order to viscous suspension is fed to line comes grinding-material and sawing.The method is commonly called " loose abrasive sawing ", and is a kind of " the 3rd main body sawing " (the 3rd main body is abrasive material).
Yet, should " loose abrasive sawing " pressure be arranged more and more because its high flow rate cost (abrasive material and line), its high Environmental costs (recycling of suspension and abandon) with and high running cost (suspension management).Therefore, this technology day by day is converted into " fixed-abrasive scroll saw ", and especially when the hardest material of cutting such as corundum.
In ' the fixed-abrasive scroll saw is cut ', the relative motion between abrasive material and the line is set as zero: abrasive material is fixed to line.This makes it to have some significant advantage:
The line wearing and tearing are less, and this is because nothing impact between particle and the line.Therefore, more preferably use running stores.
The whole momentum of particle is passed to workpiece: do not have " bonding with roll " of particle between the online and workpiece.
No longer need liquid-carrier is fed between line and the workpiece: the management of suspension and its trouble can be eliminated.Yet cooling fluid remains necessary next temperature with controllable way holding workpiece and sawline, and to wash away smear metal.
In the situation of the line of using, be dropped with the particle of crossing.Need not to adopt independent step to separate smear metal and abrasive material (in order to reuse).
Because expectation is fixed to abrasive grain on the line substrate, therefore also having the overall diameter (comprising the fixed-abrasive particle) that makes line should thin as far as possible requirement.Since usually expensive by the material of sawing, therefore force to have low kerf width, to reduce the loss of this expensive material.Therefore the fixed-abrasive sawline should be thin as far as possible, and this has limited the size of line substrate.Target is to have the line of making and totally is thinner than 150 microns.
On the other hand, exist the fixed-abrasive sawline must be able to keep the tension force that produces during the sawing process and the requirement of not rupturing.The tension force of line is higher, and more side forces can be passed on the workpiece, can realize higher cutting speed whereby.Operating line tension force in the streamline saw is at least 10 newton, typically is 25 newton, is 40 newton or more sometimes.Therefore, with the steel wire of the unusual high-tension core as line, because such line is best aspect modulus and final hot strength, this is necessary can make line thinner.
Abrasive grain also must be fixed on the line, because sawing moves to carry out with front and back usually, this motion is a kind ofly to be tending towards making particle to swing in their position range.Therefore, the larger part of sawline cross-sectional area is exclusively used on the layer that keeps abrasive grain, and this is so that requirement of strength is more difficult.
At last, line must be carried with sufficiently long length, because in many loop wire saws, actual certain-length of reaching the standard grade need to pass breadth: according to the quantity of Machine Type and ring, this breadth changes between 500 meters to 1500 meters.In many loop wire saws, single line passes in the trough of belt capstan with the form of encircling side by side.The corresponding surface of the wire loop that is arranged in parallel is called as breadth.The name of more generally using is multi-wire saw, and in fact this choose words inappropriately, because only there is single line in breadth.Therefore line must be supplied by the length with at least 10 kms, so that be used on the machine.
Current based on three kinds of major ways be used to provide the variable selection of producing fixed-abrasive sawing line.
First kind of way wherein, is generally adamantine abrasive grain and is embedded in the nickel coating by plating or electroless deposition by the nickel electrolyte that comprises diamond particles by technical staff's employing of being familiar with making Metal Substrate fixed-abrasive instrument (such as saw blade).Described an embodiment among the EP0 982 094, wherein, metal wire (providing the embodiment of stainless steel wire) is coated with nickel and diamond.Yet the coating speed that reaches is very slow.
The second way is adopted the technical staff who is used for the chemical field on the organic bond of abrasive material by the knowledge use of attempting them, to make the fixed-abrasive sawline.Have many embodiment, US 6,070, and 570, EP 1 025 942 and WO 2005/011914 be three embodiment wherein.US 2 973 478 is early stage especially embodiment of this technology.Although this causes cost benefit and is that abrasive material is fixed on effective means on the line that is generally metal, formed cutting speed is lower than the speed that obtains in the mentioned alternate manner.
Alternate manner (such as at WO 99/46077 or US 3854898) is based on the particle soldering or be brazed into line and carry out.Yet these modes are more not preferred, because they mean excessive heat flow line, this may cause line to cause loss of strength because of thermic load.Heat load problem is for thinner diameter even more serious, because they have many surfaces in whole unit length, but comes absorbing heat without quality.
For above-mentioned all technology of mentioning, still have abrasive grain is fixed to the lip-deep challenge of line quite well.
The utility model content
Therefore, the purpose of this utility model provides the further improvement for the abrasive grain confining force of fixed-abrasive scroll saw.Another purpose also is to provide a kind of method of making this line.
According to this first aspect, the fixed-abrasive sawline is protected as product.This fixed-abrasive sawline comprises: steel core wire and the layer that is pressed into that covers described steel core wire.Abrasive grain is pressed into the described layer that is pressed into, and adhesive layer covers described layer and the described abrasive grain of being pressed into.Special feature about this line is to be pressed into layer (being known from prior art additionally), the described layer that is pressed into comprises the first metal layer that covers described steel core wire and the second metal level that covers described the first metal layer, and wherein said the first metal is softer than described the second metal.Alternatively be expressed as: the described layer that is pressed into comprises two kinds of different layers: lower soft formation and upper hard formation.
The heart yearn of described fixed-abrasive sawline is formed from steel.
Preferably, described core is made by carbon steel, but does not get rid of the steel such as stainless other kind.Steel is than more preferred such as other high-tension line of tungsten, titanium or other high-strength alloy, because it can be formed into the high-tension grade.This can realize by the extensive cold forming of circular mode by line.
The typical component of carbon steel of core that is used for the fixed-abrasive sawline is as follows:
At least the carbon of 0.70wt%, higher limit depends on other alloying element (referring to following) that forms line.
The manganese of content between 0.30 to 0.70wt%.The same strain hardening that increases line with carbon of manganese, and in the manufacturing of steel, also be used as deoxidier.
The silicon of content between 0.15 to 0.30wt%.Silicon is used to during manufacture to steel-deoxidizing.Its same with carbon helps to increase the strain hardening of steel.
Element existence such as aluminium, sulphur (below 0.03wt%), phosphorus (below 0.30wt%) should be kept to minimum of a value.
All the other compositions of steel are iron and other composition.
The existence of chromium (0.005wt% to 0.30wt%), vanadium (0.005wt% to 0.30wt%), nickel (0.05wt% to 0.30wt%), molybdenum (0.05wt% to 0.25wt%) and trace B can improve the formative of line.It is 0.090wt% to 1.20wt% that this adding alloy can make carbon content, causes the hot strength can be higher than the 4000Mpa in the drag wire.Medium line, the diameter that namely is pulled to final size line before must be selected enough greatly, to obtain such high-tension intensity.The structure that obtains is thin and the pearlitic texture of deep stretch.
Preferably, stainless steel comprises the 12%Cr of minimum of a value and the nickel of sizable amount.More preferably, the stainless steel component is austenitic stainless steel, because these stainless steels can easily be pulled to tiny diameter.Preferred component is component well known in the prior art, such as AISI302 (being " Heading Quality " HQ especially), AISI 301, AISI 304 and AISI 314." AISI " is the abbreviation of " American Iron and Steel Institute (American Iron and Steel Institute) ".
Because the main purpose that " is pressed into layer " is actually for abrasive grain is pressed into wherein, therefore, it must be suitable for being pressed into particle.The whole layer that is pressed into must be out of shape under the effect that is pressed into of independent abrasive particle particle thereupon.The special fact that exists of the utility model is, is pressed into layer and is made by two-layer: the second metal level of the first metal layer that contacts with steel core wire and the described the first metal layer of covering.The utility model is necessary to make the second layer harder than ground floor.Can estimate easily by little Vickers hardness of standard whether the second layer is harder than ground floor.With reference to ISO 6507-3 " the metal hardness test: Vickers is tested less than HV 0.2 ".The first metal layer is as the liner of plastic deformation under the effect of abrasive grain.The second metal level is as prevent the abrasive grain too dark crust that sinks to get in soft the first metal layer.
Certainly, the ground floor that is pressed into layer must be enough thick, allowing plastic deformation, should be enough thin and be pressed into the second layer of layer, and to allow the ground floor distortion.On the other hand, being pressed into layer on the whole should be not too thick because otherwise the whole intensity of line reduce, this is because a large amount of cross-sectional areas are occupied by the layer that is pressed into solid not as steel core wire.In addition, be pressed into the general thickness maintenance and abrasive grain Size dependence of layer.It is large too many to enter layer such as the fruit granule specific pressure, and then they will not be pressed into layer and suitably keep, and when they with respect to being pressed into layer too hour, the bulk strength of line will lose too much.Be pressed into the layer thickness must greater than comprise be pressed into the layer the steel core wire diameter 3.5%, can hold abrasive grain.Preferably, be pressed into the layer thickness be comprise be pressed into the layer the steel core wire diameter 7%.When the thickness that is pressed into layer greater than comprise the steel core wire diameter that is pressed into layer 10% the time, being pressed into the cross-sectional area that occupies of layer has been 36% of whole cross-sectional area, this causes the loss of the whole intensity of line not accept.
In being pressed into layer, occupy about 0.5 micron (maximum reaches to 3 microns) by the second metal level.Most preferably between 1 to 2 micron.For thin line (120 μ m), thickness is preferably between 0.5 to 1 μ m.The thickness of the second metal level is not proportional with the size of line, because it only is used as the skin of soft the first metal layer.
The suitable metal or alloy that is used for the first metal layer be for example copper, zinc, brass, bronze, tin, lead, aluminium than soft metal and alloy.More preferably zinc and copper, and copper is most preferred.
Interface between steel core wire and the first metal layer can present the roughness of a certain degree, and even can interlock.The advantage at such interface is to be pressed into layer and adheres to better steel core wire." interlocking " refers to that some protuberance in the first metal layer hooks in the corresponding recess of steel core wire.Use for this, roughness is represented as the arithmetic average deviation roughness " Ra " of determining about by the metallographic cross section.On average " Ra " must be greater than 0.50 micron, even is more preferably more than 0.70 micron.
By determine average " Ra " to get off, that is, and several pictures of the different segment of the girth of shooting line, and determine roughness " Ra ", then calculating mean value for each sections.Section girth half must be measured with different sections at least, to obtain the good coverage rate on the whole girth.Should use 500 to 1000 times magnifying power.
The suitable metal or alloy that is used for the second metal level is copper, brass, nickel, nickel-phosphorus, iron, zinc-aluminium, copper-nickel, copper-beryllium, chromium, cobalt, molybdenum or tungsten.For example the alloy of brass is more preferred, because alloy is usually always hard than the simple metal that consists of it.Further preferably nickel and iron, but nickel most preferably.Under any circumstance, the metal or alloy of requirement maintenance the first metal layer must be softer than the metal or alloy of the second metal level.
Abrasive grain can be superabrasive particles, such as diamond (natural or artificial, the latter is more preferred, because their low cost and their particle fragility), cubic boron nitride or its mixture.For the application of less needs, can use such as tungsten carbide (WC), carborundum (SiC), aluminium oxide (Al
2O
3) or silicon nitride (Si
2N
3) particle: although they are softer, they are cheap more a lot of than diamond.But diamond most preferably.
The size of abrasive grain must be selected (vice versa) according to the thickness that is pressed into layer.The shape and size of determining particle self are a kind of technical fields that belong to himself.Because particle do not have (and should not have) spherical form, therefore use for this, " size " rather than their " diameter " of particle described (because diameter means spherical form).The size of particle is the linear size (representing with micron) of being determined by any measuring method as known in the art, and be in all the time connect on the particle surface each other away from 2 line (by the major part of particle) length be connected particle surface on the length of each other hithermost 2 line (by the major part of particle) between.
Imagination falls into the kind of " miniature sand " for the size of the particle of fixed-abrasive sawline.The size of miniature sand can not be determined by the material sieving technology (they are commonly used for miniature sand) of standard again.On the contrary, they must be definite by other technology, such as, laser diffraction, direct Microscopical Method For Detection, resistance or photo sedimentation.The ANSI B74.20-2004 of standard understands these methods in more detail.For this application, when the explanation particle size, refer to the particle size of determining as by laser diffraction method (perhaps its " low angle laser light scattering " that is also referred to as).The output of this process is that intermediate sizes is d
50Particle size distribution continuous or difference (that is, half of particle be less than this size, and half of particle is greater than this size).
Superabrasive is determined size range by this standard rather than by the sieve number usually.For example, the distribution of particles in 20 to 30 micron orders have 90% at 20 microns (i.e. " d
5") to 30 microns (i.e. " d
95") between particle, and surpass 40 microns distribution of particles less than one thousandth, simultaneously intermediate sizes d
50Must be between 25.0 ± 2.5 microns.
By convention, median particle diameter (namely, have less size at half place of diameter and second half has the size of the particle of larger size) should be less than 1/12nd of the periphery of steel core wire, more preferably be should be less than 1/18th of the periphery of steel core wire, in crust, to hold well particle.On the other hand, particle can not be too little, because the removal rate of material (being the wear extent of time per unit material) becomes too low.
Linear diameter, whole how much restrictions that are pressed into layer and abrasive grain size are summarised in the Table I.As follows for the particularly preferred size of line:
How many particles must be present in the surface of sawline for, to depend primarily on the type of material to be cut.Too high density will cause power too low on the particle, and this will polish particle and reduce their cutting power.On the other hand, too low density may cause particle to tear crust, because power becomes too large, perhaps may cause too low cutting rate, because time per unit passes material without enough particles.The existence of particle can recently determining by the whole outer circumferential area of the area that is occupied by particle and line: " coverage rate ".This can be carried out SEM by the area that particle occupies with respect to whole area by particle and the calculating selecting from overall picture to have typical component.Only the middle body of line chart sheet should be used, because the side is owing to tearing of line surface is tending towards over-evaluating particle surface.
The material that the target coverage rate basis of particle will be cut, the surface smoothness variation of wanting the cutting speed that reaches or wanting to obtain.Utility model people finds, and to contemplated material, in order to have best sawing performance, the particle area should be between 1 to 50% with respect to the ratio of whole area, perhaps between 2 to 20%, perhaps even between 2 to 10%.
Adhesive layer is used for abrasive grain is kept being pressed into layer.There are two kinds of selections for adhesive layer:
A kind of is that adhesive layer can be natural metal.In this case, usually by the deposition from electrolyte metal level is applied on abrasive grain and the sheath.Adhesive layer must be relatively hard metal, because it is worn during sawing and tears.Preferably, the metal of from the group that comprises iron, nickel, nickel-phosphorus, chromium, cobalt, molybdenum, tungsten, copper and brass, selecting or alloy.Here, alloy also can be used as the adhesive layer metal, because they are tending towards the formation metallic hard than them.And, no matter having or do not add in the situation of nickel phosphorus, nickel all is preferred metal for adhesive layer.Phosphorus is so that nickel-easier extension of phosphorus layer and more wear-resisting.
Alternatively, adhesive layer can be organic adhesive layer.Organic adhesive layer can be thermosetting (being also referred to as thermosetting) organic polyhydroxyl compound.Alternatively, adhesive layer can be the thermoplasticity polymerizable compound.Because during use not deliquescing when temperature reaches higher of thermosetting polymer (in case curing), so they are more preferred for such application.Preferred thermosetting polymer is phenolic resins, melamine resin or based on acrylic acid resin or amino resins, that selects in the group such as melamine resin, Lauxite, benzoguanamine formaldehyde resin, glycoluril formaldehyde resin or epoxy resin or epoxy amine is a kind of.
More preferred (but still available) is not mylar, epoxy polyester, vinyl esters or pure acidic group resin.
Preferred thermoplastic polymer is: acrylic acid, polyurethane, urethane acrylate, poly-sour ammonia, polyimides, epoxy resin.More preferably but still available be: vinyl esters, alkyd resins, silicone, Merlon, PETG, polybutylene terephthalate (PBT), polyether-ether-ketone, vinyl chloride-base polymer.
Listed that enumerate and non-exhaustive, therefore can determine the polymer that other is suitable.
Being pressed into layer and particle can process by enough organic agents, to improve the adhesion between polymer-bonded layer and the particle.
The fixed-abrasive sawline of fixed-abrasive sawline of the present utility model and prior art is clearly distinguished and is, for cross section, radially has the second metal level that has been pushed into softer the first metal layer below the abrasive grain that is pressed into.This feature can find, even the second metal level and adhesive layer same metal both.
Preferably, the rough interfaces between described the first metal layer and the described steel core wire is recognizable in perpendicular to the metallographic cross section in the plane of described sawline, and the arithmetic average deviation roughness Ra of described rough interfaces on average is higher than 0.50 micron.
Preferably, the described material of described adhesive layer is the metal of described the second metal level.
Preferably, the described material of described adhesive layer is organic adhesive material.
According to second aspect of the present utility model, provide a kind of method of making the fixed-abrasive sawline.The method may further comprise the steps:
Steel core wire is provided.The steel of this steel core wire should have the component of the row of defined in according to the application the 18th section and the 19th section.The hot strength of steel core wire be selected as so that finish the method the institute in steps after, final fixed-abrasive sawline must have the high fracture load that must be enough to stand sawing process.Because be pressed into the intensity that layer and adhesive layer do not increase line usually, therefore, the steel core wire in fact at least fixed-abrasive sawline with final is the same firm.This means for steel core wire, must satisfy following minimum fracture load (Table II)
| Steel core wire diameter (μ m) | Minimum fracture load (N) |
| 120 | 40 |
| 175 | 75 |
| 250 | 120 |
Table II
In second step, cover described steel core wire with the first metal layer, this causes forming the first medium line.For example and preferably, this is by applying to carry out with a kind of mode with electrolysis of for example selecting from copper, zinc, brass, bronze, tin, lead or aluminium.The thickness of layer is selected according to Table I.
In third step, apply this first medium line with the second metal level, this causes forming the second medium line.In addition, this is preferably by a kind ofly coming mode with electrolysis to apply and preferably carry out with for example selecting from copper, brass, nickel, iron, zinc-aluminium, copper-nickel, copper-beryllium, chromium, cobalt, molybdenum or tungsten.The metal of the first metal layer must be softer than the metal of the second metal level.The thickness of this layer between 0.5 to 3 μ m, and with the diameter of steel core wire proportional (less diameter preferably has the second thinner metal level).
In the 4th step, the little material of abrasive material of preferred size (seeing Table I) is pressed into described the second medium line.Compare relatively softly with the little material of abrasive material owing to be pressed into layer, therefore, this relatively easily carries out.For instance, by line down is pressed between two sheaths of feeding, wherein form the groove that fits tightly line profile.Abrasive grain is supplied between groove and the line with required feed rate, and sheath pushes particle and is pressed into layer simultaneously.Like this, obtain the 3rd medium line.
At last, apply described the 3rd medium line with adhesive layer, this adhesive layer can be metalline or organic nature.When adhesive layer was metal, for instance, its electro-deposition by preferred adhesive layer metal applied, preferred adhesive layer metal can be from copper, brass, nickel, nickel-phosphorus, iron, zinc-aluminium, copper-nickel, copper-beryllium, chromium, cobalt, molybdenum or tungsten select a kind of.Most preferably nickel or nickel-phosphorus.For nickel-phosphorus, preferred electroless plating mode.
Alternatively, adhesive layer can be organic.In this case, the second medium line or the 3rd medium line can be processed with adhesion promoter, and described promoter being suitable for increases the adhesion between organic coating and the medium line surface.Organic coating can be by powder coated, extruding, dipping, then applied by mould wiping or any other suitable technology.Based on the type of coating, must and then carry out cure step, this cure step be in essence heat or by ultraviolet ray or infrared radiation.Suitable coating material is from comprising phenolic resins, melamine resin or based on acrylic acid resin or amino resins, that selects in the group such as melamine resin, Lauxite, benzoguanamine formaldehyde resin is a kind of.
This process is by finishing the coil of wire on the suitable carrier such as capstan winch.
These process steps can be carried out independent of one another, and perhaps some process steps can make up.For example, be pressed into and provide the step of adhesive layer easily to be made up.
In another preferred embodiment of the method, the first medium line was subject to the tractive operation before being coated with the second metal level.Apply the first metal layer and therefore can carry out at thicker steel core wire, but must be naturally proportional with respect to the thickness of wanting the final steel core wire that obtains.Certainly, must consider the tractive loss (that is, must form than the slightly thick coating of thickness that needs) of ground floor.Tractive loss is the coating material loss that occurs during the online tractive.And the strain hardening of steel must be determined modestly, so that the final steel heart yearn has suitable hot strength.Benefit on the one hand is, because the first metal layer is made by the soft metal softer than steel, therefore supposes the not mutually diffusion of steel of metal and the core of the first metal layer, then will form coarse interlocking interface during tractive.Such rough interfaces helps to improve the adhesion between the first metal layer and the steel core wire.Other method step is implemented as hereinbefore.
As the second preferred embodiment of the present utility model, carry out the tractive operation at the second medium line.In addition, apply the consideration identical with the first preferred embodiment: the thickness of layer must be by proportional, and the strain hardening of tractive loss and line must be considered.And the interface between steel core wire and the first metal layer will be coarse.
Benefit on the other hand is that the tractive condition will be selected as so that the metal of the second metal level is diffused in the metal of the first metal layer.Therefore, the tractive condition must be so that produce local enough heat during the tractive in order to produce to be diffused in.Therefore alloy-layer becomes the second metal level.Therefore particularly preferred metal connects copper as the ground floor that deposits zinc on its top.Zinc helps to improve drawdown, and during the drawing-off, itself and copper form alloy, brass is formed the second metal level.Alternatively, instead of zinc, tin can be used, and this causes forming the second metal level with bronze.
Description of drawings
Fig. 1 a shows the whole cross section according to the line of utility model, and the enlarging section that wherein is pressed into abrasive grain has been shown in Fig. 1 b.
Fig. 2 shows the contrast sawing result who obtains with sawline of the present utility model and reference line.
The specific embodiment
According to the first embodiment of the present utility model, have the nominal carbon content and be 0.925wt% and the component line bar (nominal diameter be 5.5mm) that scribble high-carbon, be mixed with chromium the same with the 18th section component and peeled with chemical mode according to the known method of prior art.Described line is by the dried 3.05mm that is pulled to, then by patent and again by the dried mid diameter that is pulled to 0.87mm.This medium line will become steel core wire.The copper coating of every kilogram of about 341 grams of steel wire is electroplated on this mid diameter, and forms the overall diameter of 0.99mm.
In the wet wire drawing operation, this medium line is continued tractive by continuous less mould, until obtain 137 microns overall diameter (steel core wire and the first metal layer): the diameter of steel core wire is approximately 119 microns, and the thickness of the first metal layer is approximately 9 microns.This is the first medium line described in the claim to a method.Copper coating is the first metal layer described in the claim to a product.The part of this first medium line is kept somewhere to make line of the present utility model, and another part is for the manufacture of traditional line.
Traditional line forms by by diamond particles mechanically is pressed into the copper layer diamond particles being pressed in the copper layer.The median diameter of diamond particles is 10 μ m.Particle is pressed in the copper layer by line being guided through one group of close-fitting trough of belt pulley, wherein supplies diamond between the trough of belt pulley.Subsequently according to the principle of describing among the applicant's the WO 2007/147818 in spool-reel device, by with the adhesive layer electro-deposition of nickel about 4 to 5 μ m and described particle is fixed to the particle.This is taken as reference line.
Line of the present utility model before particle is pressed into it at first coating be stamped the second metal level.Nickel dam (the second metal level) therefore is deposited on the copper layer (the first metal layer) by plating with the known way among the WO 2007/147818.Nickel dam is harder than copper layer.The copper layer is expressed about 88N/mm
2The Vickers hardness of (under the 0.098N load that continues 10 seconds).It is thick that this nickel dam is approximately 1 to 2 μ m.Nickel coating has usually above 850N/mm
2Microhardness.This is the second medium line described in the claim to a method.
The same type of abrasive grain is pressed into and the identical material that is used for reference line exactly with size, that is, median diameter is the diamond particles of 10 μ m.In addition, by bonding nickel dam immobilized particles, difference is that nickel coating reduces slightly: about 4 μ m are thick.
The maintenance intensity of formed line is 43N.Its cross section is shown in Figure 1.Fig. 1 a shows the cross section 100 of complete line.Steel core wire 110 is clear and legible, in addition also promising be pressed into the layer ground floor 112, that is, and the copper layer.Therefore being all 114 owing to be pressed into the second metal level and the adhesive layer of layer, is uniform when not existing when being pressed into them to present.Yet, when watching in more detail Fig. 1 b, clearly as seen, radially below abrasive grain, have (between online 120 and 122) thin nickel dam.According to the distortion of the first metal layer, can infer that the second metal level must exist before particle is pressed into.
This cross section also is clearly shown that the rough interfaces (at length being expressed as 124) that is positioned between steel core wire 110 and the first metal (copper) layer 112.This rough interfaces is because the tractive of copper covered wire causes.The average roughness Ra at interface is approximately 1.37 μ m.Should believe that this rough interfaces helps ground floor is adhered on the steel core wire.
Reference line and line of the present utility model are all tested in the single line saw device of the type RTS-480 that is obtained by DWT.One is of a size of 25 * 125mm
2Monocrystalline silicon cut from shorter side, that is, sawline contacts with silicon on the length of 25mm.With the constant table velocity mode operation of 4.5m/min, average linear speed is 450m/min to this machine under the line tension of 12N.This saw is reciprocal, and the line of about 180m passes piece on every half period.During sawing, the arch height of monitoring line, this arch height is taken as estimating of cutting power loss.If arcly during cutting increase too soon, then line loses its cutting power rapidly, and this may be because (other reason itself that loads such as diamond polishing or line can not be excluded) that carat loss causes.Best line is the line that demonstrates low arc growth during sawing.
Fig. 2 shows the result of these tests.In abscissa, draw the sawing time.In ordinate, draw during the sawing formed arc.In first five minutes of cutting, arc being formed.Afterwards, arc stable, and produce constant duty.In first five minutes, between different lines and indifference, this initial sawing performance that represents them is without too different.In stable state, the difference between reference line and fixed-abrasive sawline of the present utility model is apparent, and this is because the gradient of curve is different.When at least during square line, obtaining following result (Table III) by the point-rendering after the starting stage
Table III
Finally arc is observe when cutting finishes arc.It is for measure cutting power when cutting finishes: arc higher, cutting power is lower.
The utility model people hypothesis, although this hypothesis should not be used to limit by any way the utility model, this is to have the second thin harder metal level before because exist minute-pressure to enter, but particle is kept preferably, because during being pressed into, when particle was pushed into soft the first metal layer, the second metal level " was sealed ", " encapsulation " described particle.As a result, the utility model people thinks that particle is kept preferably.
Claims (10)
1. fixed-abrasive sawline, it comprises: steel core wire; Cover the layer that is pressed into of described steel core wire; Abrasive grain, described abrasive grain are pressed into the described layer that is pressed into; And adhesive layer, described adhesive layer covers described layer and the described abrasive grain of being pressed into,
It is characterized in that: the described layer that is pressed into comprises the first metal layer that covers described steel core wire and the second metal level that covers described the first metal layer, and wherein said the first metal layer is softer than described the second metal level.
2. fixed-abrasive sawline according to claim 1, wherein, the thickness of described the second metal level is between 0.5 to 3 μ m.
3. fixed-abrasive sawline according to claim 1, wherein, described the first metal layer comprises one of following metal or this metal alloy: copper, zinc, brass, tin, lead, aluminium.
4. fixed-abrasive sawline according to claim 3, wherein, rough interfaces between described the first metal layer and the described steel core wire is recognizable in perpendicular to the metallographic cross section in the plane of described sawline, and the arithmetic average deviation roughness Ra of described rough interfaces on average is higher than 0.50 micron.
5. each described fixed-abrasive sawline in 4 according to claim 1, wherein, described the second metal level comprises one of following metal or this metal alloy: copper, brass, nickel, iron, zinc-aluminium, copper-nickel, copper-beryllium, chromium, cobalt, molybdenum, tungsten.
6. fixed-abrasive sawline according to claim 5, wherein, the material of described adhesive layer is following metal or this metal alloy: copper, brass, nickel, nickel-phosphorus, iron, zinc-aluminium, copper-nickel, copper-beryllium, chromium, cobalt, molybdenum, tungsten.
7. fixed-abrasive sawline according to claim 6, wherein, the described material of described adhesive layer is the metal of described the second metal level.
8. fixed-abrasive sawline according to claim 5, wherein, the described material of described adhesive layer is organic adhesive material.
9. fixed-abrasive sawline according to claim 8, wherein, the adhesive layer of described organic adhesive material comprises one of following material: phenolic resins, melamine fluosite or based on acrylic acid resin or amino resins, such as melamine resin, Lauxite, benzoguanamine formaldehyde resin, glycoluril formaldehyde resin or epoxy resin or epoxy amine.
10. fixed-abrasive sawline according to claim 1, wherein, described abrasive grain is one of following material: diamond, natural diamond, cubic boron nitride, tungsten carbide, carborundum, aluminium oxide, silicon nitride.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP10189168.7 | 2010-10-28 | ||
| EP10189168 | 2010-10-28 |
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| Publication Number | Publication Date |
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| CN202640582U true CN202640582U (en) | 2013-01-02 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN 201120424277 Expired - Fee Related CN202640582U (en) | 2010-10-28 | 2011-10-28 | A fixed abrasive sawing wire |
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| Country | Link |
|---|---|
| CN (1) | CN202640582U (en) |
| TW (1) | TWI533960B (en) |
| WO (1) | WO2012055711A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107427943A (en) * | 2015-03-13 | 2017-12-01 | 江阴贝卡尔特合金材料有限公司 | The manufacture method of consolidation abrasive saw silk with metal alloy fixed bed and manufactured saw silk |
Family Cites Families (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2793478A (en) | 1954-05-24 | 1957-05-28 | Bjorksten Res Lab Inc | Cutting tool and method of making |
| US3854898A (en) | 1970-02-19 | 1974-12-17 | Remington Arms Co Inc | A method for producing armored rod and wire saws |
| DE3147287C2 (en) | 1981-11-28 | 1984-07-05 | Messner, Caspar O.H., Prof.Dr.sc.techn., Zürich | Method of making a cutting wire |
| JPH0523965A (en) * | 1991-07-19 | 1993-02-02 | Kanai Hiroyuki | Wire for wire saw and manufacture thereof |
| JPH09150314A (en) * | 1995-11-27 | 1997-06-10 | Asahi Daiyamondo Kogyo Kk | Wire saw and manufacture thereof |
| WO1998035784A1 (en) | 1997-02-14 | 1998-08-20 | Sumitomo Electric Industries, Ltd. | Wire-saw and its manufacturing method |
| TW431924B (en) | 1998-03-11 | 2001-05-01 | Norton Co | Superabrasive wire saw and method for making the saw |
| DE19839091A1 (en) | 1998-08-27 | 2000-03-09 | Kempten Elektroschmelz Gmbh | Saw wire |
| ES2247964T3 (en) | 1999-02-04 | 2006-03-16 | Ricoh Company, Ltd. | WIRE SAW WITH ABRASIVE WIRE AND PROCEDURE FOR MANUFACTURING THE ABRASIVE WIRE. |
| US6915796B2 (en) | 2002-09-24 | 2005-07-12 | Chien-Min Sung | Superabrasive wire saw and associated methods of manufacture |
| DE602005014019D1 (en) * | 2005-12-27 | 2009-05-28 | Japan Fine Steel Co Ltd | FIXED GRINDING WIRE |
| EP1870496A1 (en) | 2006-06-20 | 2007-12-26 | NV Bekaert SA | An apparatus and method for electroplating a substrate in a continuous way. |
| TW201043367A (en) * | 2009-02-13 | 2010-12-16 | Bekaert Sa Nv | Fixed abrasive sawing wire |
-
2011
- 2011-10-14 WO PCT/EP2011/067984 patent/WO2012055711A1/en active Application Filing
- 2011-10-19 TW TW100137877A patent/TWI533960B/en not_active IP Right Cessation
- 2011-10-28 CN CN 201120424277 patent/CN202640582U/en not_active Expired - Fee Related
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107427943A (en) * | 2015-03-13 | 2017-12-01 | 江阴贝卡尔特合金材料有限公司 | The manufacture method of consolidation abrasive saw silk with metal alloy fixed bed and manufactured saw silk |
| CN107427943B (en) * | 2015-03-13 | 2019-07-05 | 江阴贝卡尔特合金材料有限公司 | The manufacturing method of consolidation abrasive saw silk with metal alloy fixing layer and manufactured saw silk |
Also Published As
| Publication number | Publication date |
|---|---|
| TW201236786A (en) | 2012-09-16 |
| WO2012055711A1 (en) | 2012-05-03 |
| TWI533960B (en) | 2016-05-21 |
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Effective date of registration: 20170301 Address after: No. 358 East Binjiang Road, Jiangyin, Jiangsu, China Patentee after: Jiangyin Bekaert Alloy Materials Co., Ltd. Address before: Belgium, Graham Weaver Patentee before: NV Bekaert SA |
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Granted publication date: 20130102 Termination date: 20191028 |
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