Background technology
Diamond, carborundum, cubic boron nitride all are that hard material, particularly diamond are higher than general material owing to its hardness, therefore are commonly used to make the instrument of cutting processing, but also because its hardness is higher than general material, therefore in processing and manufacturing certain difficulty are arranged.The present existing sawn timber that much utilizes diamond to be attached to make on the wire rod cutting hard article, yet because difference is excessive on the material hardness, therefore diamond is difficult for being attached on the wire rod, and come off easily, cause line according to impaired or because cutting speed is too low can't bear to be used, or too fast because cutting speed, resistance is excessive and make problem such as scroll saw fracture.
Existing band abrasive material scroll saw mainly contains that roll extrusion is embedded, extruding or impact style, resinoid bond consolidation style, plating or compound plating mode are prepared from, and wire saw diameters is less than 5mm.
The roll extrusion embedded mode is directly diamond or other abrasive materials to be embedded in the wire rod matrix by the mechanism roll extrusion, United States Patent (USP) 4485757 once proposed a kind of technology for preparing continuous diamond fretsaw with the roll extrusion embedded mode, the diamond coatings diameter of the diamond fretsaw of this kind technology preparation evenly and thickness and line footpath are inhomogeneous is difficult to produce greater than 120 meters long diamond wires.And, by mechanism the super hard abrasive roll extrusion is embedded in the wire rod matrix, also greatly reduce the intensity of wire rod.
Extruding or impact style are by the impact extrusion pressure head mould more than the bidimensional, below the surface with the extruding of diamond or abrasive grain, punching press inlet wire material, press the surface of the abrasive material scroll saw that forms then in impact extrusion, apply metal, the nonmetallic materials of one deck 1-10 micron.The advantage of this method is to form automatic production line, can prepare more than the length 50km, the continuous abrasive material scroll saw that diameter is even, wear resistence is good, and production cost is low.But its shortcoming is the same with the roll extrusion embedded mode, is exactly the intensity that the direct punching press inlet wire of abrasive grain material surface can reduce wire rod greatly.
The resinoid bond consolidation style is by thermosetting resin or light-cured resin abrasive grain to be bonded on the wire rod, mention abrasive material and filler on fixing with resin on the high-strength wire material as the patent of the common application of the Sumitomo Electrics Industry Ltd of Osaka, Japan and Osaka Diamond industry Co., Ltd, the abrasive material size is not less than 2/3rds of resin-bonded layer thickness, and filler size is less than 2/3rds of adhesive thickness.Resin solidification during scroll saw is made need heat and sintering circuit, and therefore, this scroll saw manufacturing speed can only be brought up to about 10 meters of per minutes.The Buddha's warrior attendant scroll saw abrasive material size of this resinoid bond solidified diamond preparation is more big, and cutting speed is fast, but that cutting speed changes in time is bigger, simultaneously all to exist abrasive material to control intensity not high for this diamond fretsaw, poor heat resistance, wearability is low, adds problems such as scroll saw serious wear in man-hour.
The mode of plating or compound plating, be by electroplating, the mode of plating and the compound plating of chemical plating, abrasive material is dissolved in the plating bath, be mixed in uniformly in the coat of metal and be attached to and prepare on the wire rod, this mode is that depositing metal layers buries abrasive grain and hold is not enough in the aqueous solution, and the life-span of abrasive material scroll saw is short, therefore can't fundamentally solve the problem that abrasive grain comes off.
In addition abrasive grain is welded to the preparation method on the wire rod in addition, this method need be carried out under hot conditions usually, and is therefore bigger to the damage of wire rod and abrasive material.
The utility model content
The technical problems to be solved in the utility model is: in order to solve the problem that abrasive grain comes off, the utility model provides a kind of band abrasive material scroll saw, refers in particular to adhere to the band abrasive material scroll saw of hard abrasive grain difficult drop-off.This scroll saw is used for cutting material and the workpiece that saw is difficult to cut saw, including, but not limited to quartz, aluminium oxide, silicon wafer, glass, metal, jewel, cement, stone material and brick and tile etc.
The technical scheme that its technical problem that solves the utility model adopts is: a kind of band abrasive material scroll saw, comprise metal wire rod and the bearing bed that contains the metal compound abrasive material that is coated on metal wire material surface, described metal compound abrasive material is all or part of abrasive grain that is coated with the metal compound layer in surface, and there is chemical bond linkage in the top layer of described metal compound layer and abrasive grain outside physical bond power.Abrasive grain is metallized and closes layer all coating or part coating, and there is chemical bond linkage in the top layer of metal compound layer and abrasive grain outside physical bond power such as Van der Waals force.Therefore abrasive grain is controlled firmly, solved abrasive grain and be difficult for being attached on the wire rod, and the technical problem that comes off easily.
As preferably, described metal wire rod adopts stainless steel wire, carbon steel steel wire, copper-plated steel wire, galvanized steel wire or brass plating steel wire.Described metal wire rod adopts single line, twisted wire or the braided wire of straight single line, process predeformation.
As preferably, described abrasive grain adopts one or more hard materials in diamond, carborundum, cubic boron nitride, aluminium oxide, zirconia, silicon nitride or the tungsten carbide.
As preferably, described metal compound layer material adopts the alloy material based on nickel, copper, tin, zinc, aluminium or silver.
In order to improve the vigor that the metal compound layer is combined with abrasive grain, reduce the condition that the metal compound layer forms, convenient high efficiency processing, to guarantee the performance of metal compound layer, add activated material, also contain activated material in the described metal compound layer, described activated material is one or more in silicon, titanium, chromium, manganese, boron and the aluminium, the percentage by weight of described activated material surpass at least alloy material in the metal compound layer overall 0.1%.
Bearing bed by electroplate, heat is stained with, coating, chemical plating or the part or all of coated metal chemical combination of compound plating mode abrasive material;
Bearing bed is by further heating, and metal or alloy metallizing abrasive surface wherein and metal wire material surface produce the alloy combination, thus further strengthen between basic wire rod, the bearing bed metallizing abrasive material in conjunction with fastness.
In order to make the more firm of metal compound abrasive material combination, difficult drop-off also is coated with the composite bed that one deck at least is used for covering the metal compound abrasive material on the described bearing bed.Described composite bed is resin bed, metal level or alloy-layer.
In order to improve wearability, described composite bed also is added with inorganic filler, and described inorganic filler is of a size of the 1/30-3/4 of abrasive grain.
The preparation method of above-mentioned band abrasive material scroll saw comprises following processing step:
1) adhesive allocating technology: adhesive is dissolved in the organic solvent, stir;
2) soak into technology: abrasive grain is immersed in the deployed adhesive, make the surface-coated of abrasive grain that organic solution be arranged;
3) abrasive grain and the alloy powder that obtain coated technology: with step 2) are puddled, and make alloy powder be attached to the abrasive grain surface, remove unnecessary alloy powder again;
4) heating process: will be attached with the abrasive grain of alloy powder and a large amount of particulate oxide ceramic powder and puddle to be placed on and hold in the tool, place vacuum furnace again or be filled with under the condition of protective gas and heat, make alloy powder heating and melting and be incubated 5 minutes-40 minutes;
5) process for cooling: in addition cooling and filtration with heating back abrasive grain in the step 4) form the metal compound abrasive material;
6) attach process: adopt coating, hot dipping, plating, chemical plating or compound plating mode, the metal compound abrasive material is attached to the surface of metal wire rod by bearing bed;
7) metallurgical binding technology: the wire rod that obtains short time single or multiple heating steps 6) makes the top layer of bearing bed metallizing abrasive material produce metallurgical binding;
8) post processing and process for cooling: after the wire rod process post processing and cooling that obtain in the step 7), can comprise steps such as follow-up lonneal, prepare band abrasive material scroll saw;
Mode of heating in the described step 7) adopts the surface heating, and heating-up temperature is 180 ℃-800 ℃, and single heat time heating time is 2-60 second.
As preferably, comprise 5-300 metal compound abrasive material on every millimeter band abrasive material scroll saw.
As preferably, the adhesive described in the step 1) is polyethylene glycol, paraffin, and phenolic resins, wax latex, acrylic resin or epoxy resin, described organic solvent are methyl alcohol, ethanol, acetone, chloroform or banana oil.
The preparation method of band abrasive material scroll saw also is included in and processes the composite bed that one deck at least is used for covering the metal compound abrasive material on the wire surface that obtains in the step 7), described composite bed by apply, heat is stained with, the mode of plating, chemical plating or compound plating forms.
The beneficial effects of the utility model are that band abrasive material scroll saw of the present utility model has following advantage:
(1) abrasive grain is metallized and closes layer all coating or part coating, and there is chemical bond linkage in the top layer of metal compound layer and abrasive grain outside physical bond power such as Van der Waals force.Therefore abrasive grain is controlled firmly, be not easy grain.
(2) top layer of metal compound abrasive material and bearing bed be by the processing of metallurgical technology, forms metallurgyization reaction, has powerful deadlocked ability, owing to the area increasing, and rough surface, so adhesive force increases greatly, so the diamond particles difficult drop-off.
(3) heat that produces of the point of contact of abrasive grain can be transmitted to the metal compound layer by abrasive grain, so area of dissipation increases, and it is many to make that temperature reduces, thereby greatly reduces in cutting the saw process because high temperature to the infringement of abrasive grain, has prolonged the life-span.
(4) composite bed can clad metal chemical combination abrasive material improves bond strength, makes metal compound abrasive material difficult drop-off more.
The specific embodiment
By reference to the accompanying drawings the utility model is described in further detail now.These accompanying drawings are the schematic diagram of simplification, basic structure of the present utility model only is described in a schematic way, so it only show the formation relevant with the utility model.
Embodiment 1
Shown in Fig. 1,2,4, a kind of band abrasive material scroll saw comprises metal wire rod 1 and the bearing bed that contains metal compound abrasive material 23 that is coated on metal wire rod 1 surface.The surperficial all or part of abrasive grain 2-2 that is coated with metal compound layer 2-1 of metal compound abrasive material 2, there is chemical bond linkage in the top layer of described metal compound layer 2-1 and abrasive grain 2-2 outside physical bond power, abrasive grain 2-2 selects diamond particles for use, and metal wire rod 1 is selected galvanized steel wire for use for the single line material.
The preparation method of band abrasive material scroll saw is as follows:
1) adhesive allocating technology is dissolved in phenolic resins in the ethanol by finite concentration, stirs, according to viscosity and the mobile concentration (concentration is more big, and the genus chemical combination layer of the cladding diamond of gained is just more thick) of adjusting;
2) coating processes places strainer with diamond abrasive, immerse again in the deployed solution of adhesive, via shake puddle after, strainer is mentioned, redundant solution is missed, make diamond surface apply organic solution;
3) coated technology, with surface-coated diamond and a large amount of copper-titanium alloy powder of organic solvent in cylinder, puddle, make alloy powder be coated on adamantine surface uniformly, with screen cloth unnecessary alloy powder is removed then;
4) heating process, after the diamond of coated copper-titanium alloy powder and a large amount of particulate alundum (Al powder are puddled, place oxide ceramic to hold tool, be put in the vacuum drying oven again and heat, (temperature and time of heating was decided according to material in 13 minutes in heating under 1000 degree, but be not limited to this), with copper-titanium alloy powder heating and melting and be incubated 5 minutes;
5) process for cooling is cooled off and the batch mixing after the heating in the step 4) with screen filtration, obtains the metal compound diamond abrasive;
6) attach process adopts the mode that applies, and gun-metal powder and metal compound diamond is joined in the epoxy resin, and stir, (by regulating the adamantine amount of metal compound, deciding final adamantine distribution density); With galvanized steel wire by in the mould that fills with above-mentioned batch mixing, and by the hole in the mould, with the method for making of similar electric wire enamel-covered wire batch mixing is attached to around the steel wire uniformly, by bearing bed 3 the metal compound diamond particles is adhered on the steel wire, form the wire rod that is compounded with the metal compound diamond abrasive behind the resin solidification.
7) metallurgical binding technology adopts the surface heating, and the wire rod (be not limited to and adopt the glowing furnace heating) by preparing in the glowing furnace intermediate frequency short time heating for multiple times step 6) impels the top layer of bearing bed 3 metallizing diamond abrasives to produce metallurgical binding.Heating-up temperature is 220 ℃, and typical single heat time heating time is 45 seconds.
8) post processing and process for cooling after the wire rod in the step 7) cooled off, can comprise follow-up steps such as lonneal, and cleaning-drying obtains final band abrasive material scroll saw.
Embodiment 2:
Shown in Fig. 1,2,4, a kind of band abrasive material scroll saw comprises metal wire rod 1 and the bearing bed that contains metal compound abrasive material 23 that is coated on metal wire rod 1 surface.The surperficial all or part of abrasive grain 2-2 that is coated with metal compound layer 2-1 of metal compound abrasive material 2, there is chemical bond linkage in the top layer of described metal compound layer 2-1 and abrasive grain 2-2 outside physical bond power, abrasive grain 2-2 selects diamond particles for use, and metal wire rod 1 is selected the brass plating steel wire for use for the single line material.
The preparation method of band abrasive material scroll saw is as follows:
1) adhesive allocating technology is dissolved in cetomacrogol 1000 0 in the methyl alcohol, stirs;
2) coating processes places strainer with diamond, immerse again in the deployed solution of adhesive, via shake puddle after, strainer is mentioned, redundant solution is missed, make diamond surface apply organic solution;
3) coated technology, with surface-coated diamond and a large amount of chromiumcopper powder of organic solvent in cylinder, puddle, make alloy powder be coated on adamantine surface uniformly, with screen cloth unnecessary alloy powder is removed then;
4) heating process, the diamond of coated chromiumcopper powder and a large amount of particulate Zirconium dioxide powders (also can be other oxide ceramic powder) are puddled be placed on oxide ceramic and hold in the tool, be put in the vacuum drying oven again and heat, (temperature and time of heating was decided according to material in 10 minutes in heating under 1050 degree, but be not limited to this), with copper zirconium alloy powder heating and melting and be incubated 25 minutes;
5) process for cooling is cooled off the batch mixing after the heating in the step 4) and with screen filtration, can be obtained the metal compound diamond abrasive;
6) attach process adopts the mode of electroplating, and the metal compound diamond is joined in the zinc electroplate liquid, and stir, (by regulating the adamantine amount of metal compound, deciding final adamantine distribution density); With the brass plating steel wire by in the mould that fills with above-mentioned batch mixing, under 22 ℃ of conditions, current density control was electroplated 3 minutes at 20A/dm2, and being bearing bed by the zinc metal level is attached to the wire rod that formation on the wire surface is compounded with the metal compound diamond abrasive to the metal compound diamond.
7) metallurgical binding technology adopts the surface heating, by the wire rod for preparing in the glowing furnace intermediate frequency short time heating for multiple times step 6), impels the top layer of bearing bed 3 metallizing diamond abrasives to produce metallurgical binding.Heating-up temperature is 4500 ℃, and typical single heat time heating time is 30 seconds.
8) post processing and process for cooling after the wire rod that obtains in the step 7) cooled off, can comprise follow-up steps such as lonneal, and cleaning-drying obtains final band abrasive material scroll saw.
Embodiment 3
Shown in Fig. 1,2,4, a kind of band abrasive material scroll saw comprises metal wire rod 1 and the bearing bed that contains metal compound abrasive material 23 that is coated on metal wire rod 1 surface.The surperficial all or part of abrasive grain 2-2 that is coated with metal compound layer 2-1 of metal compound abrasive material 2, there is chemical bond linkage in the top layer of described metal compound layer 2-1 and abrasive grain 2-2 outside physical bond power, abrasive grain 2-2 selects silicon-carbide particle for use, and metal wire rod 1 is selected STAINLESS STEEL WIRE for use.
The preparation method of band abrasive material scroll saw is as follows:
1) adhesive allocating technology adds epoxy resin in the ethanol, stirs;
2) coating processes places strainer with silicon-carbide particle, immerse again in the deployed solution of adhesive, via shake puddle after, strainer is mentioned, redundant solution is missed the organic solution that made the silicon-carbide particle surface-coated;
3) coated technology, with surface-coated silicon-carbide particle and a large amount of alusil alloy powder of organic solvent in cylinder, puddle, make alloy powder be coated on the surface of silicon-carbide particle uniformly, with screen cloth unnecessary alloy powder is removed then;
4) heating process, the silicon-carbide particle of coated alusil alloy powder and a large amount of particulate glass powders (also can be other oxide ceramic powder) are puddled be placed on oxide ceramic and hold in the tool, be put in the vacuum drying oven again and heat, (temperature and time of heating was decided according to material in 12 minutes in heating under 1050 degree, but be not limited to this), with alusil alloy powder heating and melting and be incubated 40 minutes;
5) process for cooling is cooled off the batch mixing after the heating in the step 4) and with screen filtration, can be obtained metal compound carbonization silicon abrasive material;
6) attach process, the mode of employing hot dipping joins metal compound carbonization silicon abrasive material in the plumbous hot solution liquid of tin, and stirs, (by regulating the adamantine amount of metal compound, deciding final adamantine distribution density); STAINLESS STEEL WIRE is immersed in the above-mentioned batch mixing, allows batch mixing be attached to uniformly on the wire rod, by bearing bed 3 metal compound carbonization silicon abrasive material is attached to wire rod and becomes face, cooling obtains being compounded with the wire rod of metal compound carbonization silicon abrasive material.
7) metallurgical binding technology, adopt the surface heating, by glowing furnace intermediate frequency short time single heating steps 6) in the wire rod for preparing, impel the top layer of bearing bed 3 metallizing silicon carbide abrasives to produce metallurgical binding, heating-up temperature is 300 ℃, and typical single heat time heating time is 60 seconds.
8) post processing and process for cooling after the wire rod that obtains in the step 7) cooled off, can comprise steps such as follow-up lonneal, and cleaning-drying obtains final band abrasive material scroll saw.
Embodiment 4
The content of present embodiment be with the difference of embodiment 2, the abrasive grain 2-2 of present embodiment selects carborundum for use, can select one or more mixing of hard material particles such as cubic boron nitride, aluminium oxide, zirconia, silicon nitride or tungsten carbide in addition for use.
Embodiment 5
The content of present embodiment be that with the difference of embodiment 2 what the wire rod of present embodiment was selected for use is the structure twisted wire, this twisted wire adopts 3 three galvanized steel wires stranded forming mutually, can select braided wire for use in addition.
Embodiment 6
As shown in Figure 3, a kind of band abrasive material scroll saw comprises metal wire rod 1 and the bearing bed that contains metal compound abrasive material 23 that is coated on metal wire rod 1 surface.The surperficial all or part of abrasive grain 2-2 that is coated with metal compound layer 2-1 of metal compound abrasive material 2, there is chemical bond linkage in the top layer of described metal compound layer 2-1 and abrasive grain 2-2 outside physical bond power, also be coated with one deck (also can be two-layer more than) on the bearing bed 3 and be used for covering the composite bed 4 of metal compound abrasive material 2, composite bed 4 is resin bed, metal level or alloy-layer, composite bed 4 also is added with inorganic filler, and inorganic filler is of a size of the 1/30-3/4 of abrasive grain 2-2.(inorganic filler can be diamond, one or more of carborundum, aluminium nitride, graphite, hexagonal boron nitride or metal and alloy powder).Abrasive grain 2-2 selects diamond particles for use, and metal wire rod 1 is selected galvanized steel wire for use for the single line material, and wire rod structure also can be twisted wire or braided wire.
The preparation method of band abrasive material scroll saw is as follows:
1) adhesive allocating technology is dissolved in phenolic resins in the ethanol by finite concentration, stirs, according to viscosity and the mobile concentration (concentration is more big, and the genus chemical combination layer of the cladding diamond of gained is just more thick) of adjusting;
2) coating processes places strainer with diamond abrasive, immerse again in the deployed solution of adhesive, via shake puddle after, strainer is mentioned, redundant solution is missed, make diamond surface apply organic solution;
3) coated technology, with surface-coated diamond and a large amount of copper-titanium alloy powder of organic solvent in cylinder, puddle, make alloy powder be coated on adamantine surface uniformly, with screen cloth unnecessary alloy powder is removed then;
4) heating process, after the diamond of coated copper-titanium alloy powder and a large amount of particulate alundum (Al powder are puddled, place oxide ceramic to hold tool, be put in the vacuum drying oven again and heat, (temperature and time of heating was decided according to material in 13 minutes in heating under 1000 degree, but be not limited to this), with copper-titanium alloy powder heating and melting and be incubated 15 minutes;
5) process for cooling is cooled off and the batch mixing after the heating in the step 4) with screen filtration, obtains the metal compound diamond abrasive;
6) attach process adopts the mode that applies, and gun-metal powder and metal compound diamond is joined in the epoxy resin, and stir, (by regulating the adamantine amount of metal compound, deciding final adamantine distribution density); With galvanized steel wire by in the mould that fills with above-mentioned batch mixing, and by the hole in the mould, with the method for making of similar electric wire enamel-covered wire batch mixing is attached to around the steel wire uniformly, by bearing bed 3 the metal compound diamond particles is adhered on the steel wire, form the wire rod that is compounded with the metal compound diamond abrasive behind the resin solidification.
7) metallurgical binding technology adopts the surface heating, and the wire rod (be not limited to and adopt the glowing furnace heating) by preparing in the glowing furnace intermediate frequency short time heating for multiple times step 6) impels the top layer of bearing bed 3 metallizing diamond abrasives to produce metallurgical binding.Heating-up temperature is 220 ℃, and typical single heat time heating time is 45 seconds.
8) wire surface that in described step 7), obtains by apply, heat is stained with, the mode of plating, chemical plating or compound plating forms composite bed 4.
9) post processing and process for cooling after the wire rod in the step 7) cooled off, can comprise steps such as follow-up lonneal, and cleaning-drying obtains final band abrasive material scroll saw.
Be enlightenment with above-mentioned foundation desirable embodiment of the present utility model, by above-mentioned description, the related work personnel can carry out various change and modification fully in the scope that does not depart from this utility model technological thought.The technical scope of this utility model is not limited to the content on the specification, must determine its technical scope according to the claim scope.