EP3580004A1 - Billes de scie à comportement d'aplatissement réduit et cordon de scie comprenant de telles billes - Google Patents

Billes de scie à comportement d'aplatissement réduit et cordon de scie comprenant de telles billes

Info

Publication number
EP3580004A1
EP3580004A1 EP18701500.3A EP18701500A EP3580004A1 EP 3580004 A1 EP3580004 A1 EP 3580004A1 EP 18701500 A EP18701500 A EP 18701500A EP 3580004 A1 EP3580004 A1 EP 3580004A1
Authority
EP
European Patent Office
Prior art keywords
saw
diameter
bead
beads
dmin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP18701500.3A
Other languages
German (de)
English (en)
Inventor
Jan Vaneecke
Tom Baekelandt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bekaert NV SA
Original Assignee
Bekaert NV SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bekaert NV SA filed Critical Bekaert NV SA
Publication of EP3580004A1 publication Critical patent/EP3580004A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28D—WORKING STONE OR STONE-LIKE MATERIALS
    • B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
    • B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
    • B28D1/08—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with saw-blades of endless cutter-type, e.g. chain saws, i.e. saw chains, strap saws

Definitions

  • the invention relates to saw beads as they are used in saw cords.
  • Saw cords are used to cut natural or manmade stone-like materials such as marble, granite, brick, concrete and like materials.
  • the invention extends also to saw cords using the inventive beads.
  • Saw cords are made of a carrier rope - that is usually a steel rope - whereon saw beads are threaded.
  • the carrier rope is closed by means of a splice into a loop - for example as described in WO 2016/188978 A1 of the current applicant - and thereafter polymer is injection moulded between the beads as for example described in WO 2013/102542 A1 of the current applicant.
  • the beads comprise a small, cylindrical metal sleeve whereon a circumferential abrasive layer is attached.
  • abrasive layer is made by metal powder metallurgy (as already described in US 2,679,839) wherein abrasive particles - usually diamond grit - are mixed with metal powders and an optional organic wax. The mixture is pressed into an annular shape and thereafter sintered at high temperature and/or high pressure. The formed annular beads are then soldered to the metal sleeve.
  • a saw bead is provided.
  • the saw bead comprises a metal sleeve.
  • the metal sleeve has an axis of symmetry.
  • the metal sleeve has an outer sleeve diameter of 'Dmin'.
  • On the outer surface of the metal sleeve an abrasive layer is provided.
  • the abrasive layer is attached to the outer circumference of the metal sleeve.
  • the abrasive layer extends radially up to a maximum diameter of 'Dmax'.
  • a 'working area A(D)' within the abrasive layer can be identified.
  • the 'working area' at diameter D is equal to the area of intersection between an imaginary cylinder and the abrasive layer.
  • the imaginary cylinder is concentric to the axis of symmetry and has a diameter D.
  • the working area on its turn defines an 'average working length L(D)' that is equal to the working area divided by the circumference of the cylinder.
  • the working area is equal to the product of the average working length and the circumference ⁇ of the cylinder.
  • A(D) express the working area that is equal to the area of intersection between the abrasive layer and an imaginary cylinder with diameter D that is concentric to the axis of the metal sleeve. 'D' decreases from Dmax towards Dmin.
  • the average working length L(D) is then equal to A(D)/ ⁇ .
  • L(D1 ) is larger than or equal to L(D2) i.e. for every D1 , D2 for which Dmin ⁇ D1 ⁇ D2 ⁇ Dmax, then L(D1 ) ⁇ L(D2).
  • the metal sleeve may comprise a closure as described in WO 201 1
  • Such metallic sleeve is normally made of low to medium carbon steels. More preferred is if the sleeve is made by metal injection moulding as described in WO 2014/082870 A1 of the current applicant. Then metal sleeve compositions are preferably iron nickel steels, stainless steels such as austenitic steels, precipitation hardenable steels and the like. Using metal injection moulding allows a large degree of freedom to make internal screwthreads to the inner side of the sleeve as described in WO 2015/180947 A1 of the current applicant.
  • the abrasive layer comprises abrasive particles that are held in a metal matrix material.
  • Possible abrasive particles are made of diamond, cubic boron nitride, silicon carbide, aluminium oxide, silicon nitride, tungsten carbide, titanium carbide or mixtures thereof but predominantly diamond, in particular manmade diamond is preferred.
  • the metal matrix materials are usually an alloy of many metals forming complex intermetallic phases.
  • the following compositions are popular (the numbers between brackets are the percentages by weight):
  • the abrasive layer is formed into an annular shape by compressing the metal powder wherein the abrasive particles are mixed at high pressure followed or combined with a high temperature treatment in order to consolidate the mixture. Thereafter the formed bead ring is brazed to the metal sleeve.
  • the abrasive layer is formed by laser cladding directly onto the metal sleeve. In this way the brazing can be omitted and in addition the abrasive layer is present down to the surface of the metal sleeve.
  • the metal matrix compositions as disclosed in WO 2016/050508 A1 of the current applicant are preferred.
  • Such metal matrices comprise at least 60 percent by weight 'wt%' of copper and between 0.5 to 10 wt% of one or more metals out of the group consisting of nickel, iron, cobalt and manganese.
  • an element out of the group consisting of tin, zinc, silver, bismuth, antimony, indium, lead, and phosphorous and between 5 and 15 wt% of metals out of the group consisting of chromium, titanium, vanadium, tungsten, zirconium, niobium, molybdenum, tantalum and hafnium can be added.
  • the diameter of the saw bead inclusive the abrasive layer i.e.
  • Dmax is up to 9 to 1 1 mm on 5 mm outer diameter metallic sleeves or up to a Dmax of 7 to 8 mm on 4 mm outer diameter metallic sleeves.
  • the abrasive layer covers about 8 to 10 mm axial length on the surface of the metallic sleeve.
  • the average working length increases strictly monotonically with decreasing diameter. This means that for every D1 and D2 between Dmin and Dmax (limits included) wherein D2 is larger than D1 , L(D1 ) is larger than L(D2) i.e. for every D1 , D2 for which
  • Prior art beads have a substantially annular abrasive layer of which the ends are planar and perpendicular to the axis of the metal sleeve. This means that the length 'L' of the abrasive layer remains constant during the use of the saw bead. During use the diameter 'D' of the bead must diminish. This is needed as the abrasive particles are worn out during sawing and must be constantly replenished with fresh abrasive particles that are revealed from the abrasive layer as the erosion progresses. The contacting surface of the bead that abrades the stone is then half the working area.
  • a flat is a part of the mantle of the bead that has a higher radius of curvature than the remaining mantle. As the flat is pressed towards the cut by the tension in the bow, it will hamper the rotation of the saw cord. As the flat has a smaller contacting surface compared to the remainder of the bead the contact pressure is increased. Consequently the bead will be worn even more at the flat i.e. the process is self-amplifying. As a result the complete loop will lock into a preferred angular position wherein one side of the loop is constantly cutting the work piece, while the diametrically opposite side rarely gets toward the work piece and hence is not sawing.
  • the average working length L(D) of the bead monotonically increases while the bead is being used. Consequently the rate of decrease of the working area of the bead that contacts the workpiece is always lower than that of a prior art bead that has constant length. If now - by one or another reason - the saw cord is prevented from rotation, the contacting surface will locally increase - due to the increasing average working length - at the flat leading to a lower working pressure and hence less wear at that flat area. As a consequence the self- amplifying mechanism is broken and the saw cord will not lock on this position.
  • Lmax is equal to the axial length of the abrasive layer at the metal sleeve diameter Dmin.
  • the ratio (Lmax/Dmin) is a convenient measure to scale the rate of increase of the average working length with decreasing diameter.
  • AL is zero as the length of the bead does not change during use.
  • the rate of average working length increase over diameter decrease AL/AD must at least be one third of (Lmax Dmin) or higher. If the value is less, there is a likelihood that flattening will occur. For prior art beads this rate is zero.
  • a particularly preferred embodiment is if the rate of average working
  • AL/AD length increase over diameter decrease AL/AD is about Lmax/Dmax. With 'about' is meant that the value of AL/AD remains within +/- 5% of
  • the increase of average working length with decreasing diameter can also be numerically expressed for the specific bead having an 'Lmax' of between 8 mm to 9 mm at Dmin and wherein Dmin is between 4.5 to 5.5 mm.
  • the average working length increases with at least 50 micrometer per 100 micrometer of decreasing diameter. If the increase of the average working length is less than 50 micrometer per 100 micrometer the working area decreases too fast and the risk for flattening increases.
  • the average working length should not increase more than 170 micrometer per 100 micrometer of decreasing diameter. If this becomes the case it becomes difficult to have sufficient reserve in the abrasive layer to be able to reach an acceptable lifetime of the bead.
  • the average working length increases with at least 75 micrometer and not more than 120 micrometer per 100 micrometer of decreasing diameter.
  • a bead with a Dmax of 8 mm and an Lmax of 8 mm an average working length increase of 100 micrometer per 100 micrometer of decreasing diameter is best as then the working area remains about constant during the use of the bead.
  • the working area remains at any time during the use of the sawing bead - except when the bead is completely worn out i.e. at Dmin - smaller than that of a prior art sawing bead with a constant length equal to the working length at Dmin. So the working area of the bead remains at any working diameter 'D' of the bead smaller than the product of the circumference of the cylinder at that working diameter and the average working length at the outer sleeve diameter Dmin and this for any diameter D strictly larger than Dmin and smaller or equal to the maximum diameter Dmax.
  • a preferred embodiment is when the abrasive particles that are held by a metal matrix in the abrasive layer are protruding from the outer surface of the abrasive layer already prior to the first sawing with the saw bead.
  • buried abrasive particles will gradually be revealed and will protrude from the working surface.
  • specific is that already prior to use, when the beads are in their virgin, unused state, the abrasive particles are protruding. In this way the saw bead will immediately start to saw and no dressing steps are required.
  • the abrasive layer comprises abrasive particles held in a metal matrix that shows a dendritic metallographic structure.
  • abrasive particles held in a metal matrix that shows a dendritic metallographic structure.
  • Such structure is particularly preferred because it has a higher hardness than alloys having a globular structure.
  • a globular structure is obtained when the abrasive sawing layer goes through thermal quasi- equilibrium processes i.e. processes wherein the cooling or heating is relatively slow to the melting and solidification processes. Examples of such quasi-equilibrium processes are the known ways to manufacture beads through the metal powder route.
  • the dendritic metallographic structures are obtained in non-equilibrium processes wherein the cooling and heating is fast compared to the melting and solidification of the metals forming the metal matrix.
  • An exemplary process is laser cladding wherein locally molten metal alloys are cooled extremely fast and result in very fine dendritic structures.
  • the surface of such a laser cladded bead will have an outer surface that - prior to first sawing, in their unused, virgin state - has abrasive particles that protrude out of the surrounding surface. I.e. such beads do not need to be post-processed in order to reveal abrasive particles before first sawing nor do they need a special initial treatment to liberate the first abrasive diamonds from the outer surface.
  • a saw cord is claimed.
  • the saw cord comprises a carrier cord - that is preferably a steel cord - and saw beads threaded thereon.
  • the saw beads have the features of at least claim 1 and possibly other features from the claims depending from claim 1 .
  • the saw beads are separated from one another by a polymer sleeve. Preferably a polyurethane polymer sleeve is used.
  • a preferred embodiment of the saw cord is that the saw beads are firmly attached to the carrier cord by means of the polymer. It is particularly important that the beads are rotationally fixed to the carrier cord in order to prevent that they start to rotate.
  • FIGURE 1 a shows a cross section of a prior art bead with different
  • FIGURE 1 b shows a cross section of a prior art bead with different
  • FIGURE 2 shows a cross section of an inventive bead through a plane that comprises the axis of the bead;
  • FIGURE 3 shows explains the definitions of working area and average working length on the contacting surface of an inventive bead;
  • FIGURE 4a and 4b respectively show the average working length and the working area of a prior art bead
  • FIGURE 5a and 5b respectively show the average working length and the working area of different preferred embodiments of the inventive bead
  • Reference numbers to parts having identical function or meaning have equal units and tens across the figures while the hundred digit refer to the number of the figure.
  • FIGURE 1 a and 1 b illustrate a prior art bead 100.
  • the bead consists of a metal sleeve 102 on top of which an abrasive layer 104 is attached.
  • the metal sleeve 102 has an axis of symmetry 1 12 and an outer sleeve diameter Dmin.
  • the abrasive layer 104 consists of abrasive particles 108 that are held in metal matrix 106.
  • the abrasive layer extends from Dmin up to Dmax which is the radial outermost diameter. Lmax is the average working length at Dmin. In the case of the prior art bead L(D) remains equal to this Lmax.
  • FIGURE 2 depicts the cross section of an inventive bead by a plane
  • a metal sleeve 202 is carrying an abrasive layer 204 that consists of a metal matrix 206 wherein diamonds 208 are embedded.
  • the inventive bead has been made by laser cladding which results in a rough outer surface 214 where some of the diamonds are protruding 208'.
  • the metal sleeve 202 has an axis of symmetry 212 and an outer diameter indicated with 'Dmin'.
  • the abrasive layer 204 extends to a maximum diameter 'Dmax'.
  • the working area A(D) is the area of the intersection of the abrasive layer 204 with an imaginary cylinder 'G' having a diameter 'D'.
  • the average working length at Dmin is equal to Lmax.
  • FIGURE 3 shows how the average working length L(D) relates to the
  • the figure represents the worn surface of a bead when its' diameter has been reduced to a diameter D. It is composed of several pictures that are stitched together.
  • Protruding diamonds 308 are visible that are followed by their 'comet tails 318'.
  • the 'comet tails' are formed in the metal matrix 306 as they are in the shadow of the protruding diamond 308: there the metal matrix material 306 is not abraded.
  • 316 and 316' indicate the edges of metal sleeve 302.
  • FIGURES 4a, 4b and 5a and 5b the working of the invention is
  • FIGURE 4a describes how the working length of a prior art bead changes during the use of the bead: as the diameter of the saw bead decreases the average working length L(D) (in mm) remains constant at 9 mm.
  • the corresponding working area A(D) (in mm 2 ) linearly diminishes from 215 mm 2 to 141 mm 2 that is a change of one third of the original working surface: see FIGURE 4b.
  • FIGURE 5a and 5b show three different cases for the inventive saw
  • the volume of the abrasive layer is 91 % of that of the prior art bead; - In the second case (depicted with a triangle 'A' and a dash dot line) the average working length of the bead increases at a rate of
  • the average working length of the bead increases at a rate of 1 .18 that is equal to Lmax/Dmax. For every 100 ⁇ in diameter that is abraded away the average length increases with 1 18 ⁇ .
  • the working area remains practically constant throughout the use of the bead. The volume is
  • the inventors made different versions of the saw beads with different levels of powder gas flow, different levels of powder speed with more or less overlap between nozzle feed and laser beam and with lower or higher
  • the Lmax was 8.1 mm and Dmin was 5 mm.
  • AL/AD 0.96, 0.984, 1 .05, 1 .085, 1 .53, 1 .667, 1 .712, 1 .75, and 2.263.
  • the beads values of 2.263 were not workable as they did not contain enough abrasive material to fulfil lifetime expectations. The other beads performed well and did show less flattening behaviour than competing products based on prior art beads.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mining & Mineral Resources (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Processing Of Stones Or Stones Resemblance Materials (AREA)

Abstract

Un problème récurrent dans l'utilisation de cordons de scie pour scier des matériaux de type pierre naturelle ou artificielle, tels que le marbre, le granit, la brique, le béton et analogues, est que, pendant l'utilisation du cordon de scie, les billes peuvent développer une face plate inhibant la rotation du cordon de scie et conduisant ainsi à une usure préférée sur un côté du cordon de scie. Étant donné qu'un seul côté des billes du cordon de scie est érodé, les cordons de scie doivent être jetés prématurément. Pour remédier à ce problème d'aplatissement, les inventeurs ont constaté qu'il est avantageux que la longueur de travail moyenne, c'est-à-dire la longueur axiale moyenne de la bille qui entre en contact avec la pièce à usiner, doit augmenter de manière monotone avec un diamètre décroissant. De cette manière, la perte de zone de contact entre la bille et la pièce à usiner due au diamètre réduit de la bille est compensée par une longueur de travail accrue. Par conséquent, la pression de contact sur la bille reste sensiblement constante pendant toute la durée de vie utile de la bille, ce qui n'est pas le cas pour les billes de l'état de la technique. Dans les billes selon l'état de la technique, la pression de contact sur la bille augmente au fur et à mesure que la zone de contact diminue avec un diamètre décroissant.
EP18701500.3A 2017-02-08 2018-02-01 Billes de scie à comportement d'aplatissement réduit et cordon de scie comprenant de telles billes Withdrawn EP3580004A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP17155169 2017-02-08
PCT/EP2018/052465 WO2018145980A1 (fr) 2017-02-08 2018-02-01 Billes de scie à comportement d'aplatissement réduit et cordon de scie comprenant de telles billes

Publications (1)

Publication Number Publication Date
EP3580004A1 true EP3580004A1 (fr) 2019-12-18

Family

ID=57995107

Family Applications (1)

Application Number Title Priority Date Filing Date
EP18701500.3A Withdrawn EP3580004A1 (fr) 2017-02-08 2018-02-01 Billes de scie à comportement d'aplatissement réduit et cordon de scie comprenant de telles billes

Country Status (3)

Country Link
EP (1) EP3580004A1 (fr)
CN (1) CN110366468A (fr)
WO (1) WO2018145980A1 (fr)

Family Cites Families (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2679839A (en) 1952-09-05 1954-06-01 Super Cut Cable variety stone cutting saw
JPH09103916A (ja) * 1995-10-03 1997-04-22 Komatsu Ltd 鉄筋構造物切断用ダイヤモンド工具及び切断方法
JP3370226B2 (ja) * 1996-02-23 2003-01-27 株式会社ノリタケスーパーアブレーシブ ダイヤモンドビーズソー
JPH09225736A (ja) * 1996-02-23 1997-09-02 Noritake Dia Kk ダイヤモンドビーズソー
KR100785512B1 (ko) * 2004-07-16 2007-12-13 이화다이아몬드공업 주식회사 와이어 쏘우용 비드 및 와이어 쏘우
CN1836869A (zh) * 2006-04-21 2006-09-27 桂林矿产地质研究院 具有等磨耗胎体结构的金刚石绳锯串珠
CN102612418B (zh) 2009-11-17 2017-02-15 贝卡尔特公司 锯绳
US9254527B2 (en) 2011-03-04 2016-02-09 Nv Bekaert Sa Method to produce a sawing bead
EP2495062A1 (fr) * 2011-03-04 2012-09-05 NV Bekaert SA Bille de sciage
CN102975292A (zh) * 2011-09-07 2013-03-20 福建万龙金刚石工具有限公司 多层钎焊金刚石串珠
CN104039490B (zh) 2012-01-05 2016-11-23 贝卡尔特公司 线锯的注射塑模、线锯的生产方法和由此得到的线锯
CN104884203B (zh) 2012-11-30 2017-10-03 贝卡尔特公司 一种制造用作锯珠的磨料层的载体的金属套筒的方法
US20170189978A1 (en) 2014-05-27 2017-07-06 Nv Bekaert Sa Metal sleeve for carrying the abrasive layer of a saw bead in a saw cord
ES2723971T3 (es) 2014-10-01 2019-09-04 Bekaert Sa Nv Método de fabricación de un elemento de sierra y elemento de sierra
EP3302861B1 (fr) 2015-05-26 2020-07-01 NV Bekaert SA Boucle de scie à câble et procédé de fabrication d'une telle boucle

Also Published As

Publication number Publication date
CN110366468A (zh) 2019-10-22
WO2018145980A1 (fr) 2018-08-16

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