JP2014181125A - Reel for winding superabrasive wire saw - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reel which can obtain a vibration reducing effect during rotation by facilitating a reduction in unbalance, which can obtain an energy-saving effect of a dynamic surface during rotary drive, and which can be manufactured at a low cost.SOLUTION: A reel 1 for winding a superabrasive wire saw includes a drum part 2 that is elongated in a direction of a winding shaft 80, and a flange part 5 that is elongated in an outer peripheral direction from the drum part 2. The drum part 2 and the flange part 5 are formed from integral matter made of an aluminum alloy casting.

Description

  The present invention relates to a superabrasive wire saw winding reel.

  As an example of a superabrasive wire saw, a fixed-abrasive diamond wire saw in which diamond abrasive grains are fixed to the surface of a core wire by a resin, nickel plating, brazing material, or the like as a binder. When this diamond wire saw is used, a material such as metal can be cut with a very good sharpness. Moreover, the slurry which mixed abrasive | polishing liquid and the abrasive grain is unnecessary, and a water-soluble or water-insoluble cutting fluid can be utilized. For this reason, it can suppress that a cutting device and its periphery are contaminated with the sludge scattered at the time of a cutting | disconnection, and can aim at the improvement of a working environment. In addition, according to this diamond wire saw, it is possible to produce a long length of several km or more. Thereby, since a plurality of cutting processes can be performed at the same time, a cutting speed several times or more can be obtained as compared with a multi-wire saw system using a slurry.

  When performing cutting using the above-described superabrasive wire saw, the superabrasive wire saw is wound around a reel, and is fed out or collected from the state toward a workpiece. For this reason, in order to make a superabrasive wire saw attachable to a cutting device, it is necessary to first wind the superabrasive wire saw around a reel corresponding to the cutting device.

  The superabrasive wire saw includes a core wire and a plurality of superabrasive particles fixed to the surface of the core wire using a binder. Unlike the case of the free abrasive grain method, the superabrasive grains are provided so as to protrude from the surface of the binder. A superabrasive wire saw is wound around a surface of a reel formed in a cylindrical shape in multiple layers while reciprocating between both ends of the surface. The superabrasive wire saw is wound in multiple stages at a constant pitch between both ends of the surface of the reel, and adjacent superabrasive wire saws are in contact with each other.

The following prior arts are known as conventional reels of this type.
Japanese Patent Laid-Open No. 11-114798 (Patent Document 1) discloses a reel around which a superabrasive wire saw or the like is wound. A reel in which an aluminum alloy is press-fitted into the part is disclosed.

  In this way, the reel is aimed at the effect that the superabrasive wire saw does not break due to the body part not being deformed and the gap between the flange part and the body part being caught.

  Japanese Patent Application Laid-Open No. 2000-317805 (Patent Document 2) discloses a reel in which a nut that can be used to attach a reel to a wire saw cutting machine is provided at the tip of the reel, and the recess can be closed with a lid. Has been.

  The reel is intended to prevent slurry and the like from adhering to the nut so that the nut loosening operation is not hindered. This type of reel is made of steel.

  Japanese Patent Application Laid-Open No. 2002-370152 discloses an assembly-type reel in which a flange portion and a body portion are separately formed.

Japanese Patent Laid-Open No. 11-114798 JP 2000-317805 A Japanese Patent Laid-Open No. 2002-370152

  However, conventional reels made of steel are heavy and difficult to accurately adjust the dynamic balance, causing vibrations in the wire saw cutting machine and causing the superabrasive wire saw to break. In some cases, this may cause a poor accuracy of the cut surface of the workpiece.

  Furthermore, in an assembly-type reel in which the heel portion and the body portion are separately formed, the superabrasive wire saw may be caught in the gap between the heel portion and the body portion, causing disconnection.

  Compared to conventional steel reels, the present invention can easily reduce unbalance, obtain a vibration reduction effect during rotation, obtain an energy saving effect related to power plane and transportation during rotation driving, and can be manufactured at low cost. It is to provide a reel that can be manufactured at

  A superabrasive wire saw winding reel according to the present invention includes a drum portion extending in a winding axis direction and a flange portion extending from the drum portion in an outer peripheral direction, and the drum portion and the flange portion are casted from an aluminum alloy. It is formed by the integral thing which consists of.

  In the superabrasive wire saw winding reel configured as described above, the drum portion and the flange portion are formed of an integral body made of an aluminum alloy casting, so that the reel is light in weight and unbalance can be easily reduced. The vibration lowering effect can be obtained. Further, it is possible to provide a reel capable of producing an energy saving effect in terms of power and transportation during rotation driving, and which can be manufactured at low cost.

  Preferably, the composition of the aluminum alloy is 85 to 98 mass% for Al, 0.5 mass% or less for Si, 0.25 mass% or less for Cu, and 2 to 10 mass% for Mg.

Preferably, the hardness of the aluminum alloy is 40 or more in terms of Brinell hardness.
Preferably, the breaking elongation of the aluminum alloy is 5% or more. In addition, the measuring method of breaking elongation follows JISZ2241.

  Preferably, the superabrasive wire saw has a core wire with a diameter of 0.03 mm to 0.5 mm.

Preferably, the winding tension of the superabrasive wire saw is 3N to 40N.
Preferably, the winding pitch of the superabrasive wire saw is 0.05 mm to 3.0 mm, and the number of winding stages is two or more.

  Preferably, the specification is for one-use use, i.e., the supplier does not collect the reels again once they are delivered to the customer.

  Preferably, the surface roughness of the drum portion and the flange portion in contact with the superabrasive wire saw is Ra 3.2 μm or less.

It is a perspective view which shows the superabrasive wire saw wound around the reel for superabrasive wire saw winding in embodiment of this invention. It is a schematic diagram which expands and shows the superabrasive wire saw in FIG. It is a schematic diagram which shows the cross section along the III-III line | wire in FIG. It is sectional drawing along the IV-IV line in FIG. It is a perspective view which shows the superabrasive wire saw cutting device in embodiment of this invention.

  FIG. 1 is a perspective view showing a superabrasive wire saw wound around a superabrasive wire saw winding reel according to an embodiment of the present invention. Referring to FIG. 1, a superabrasive wire saw 10 is wound in multiple layers on the outer peripheral surface of a reel 1 formed in a cylindrical shape. As will be described in detail later, in the superabrasive wire saw winding structure in the present embodiment, the pitch P at which the superabrasive wire saw 10 is wound around the outer peripheral surface is set within a predetermined range.

In addition to slicing silicon wafers from silicon ingots, superabrasive wire saw 10 is made of cemented carbide, cermet, ceramics, germanium, ferrite, sendust, alnico, samarium cobalt, neodymium magnet, glass, crystal, sapphire, stone, refractory brick , Tiles, resin materials, FRP (fiber-glass reinforced plastic), CFRP (carbon fiber reinforced plastic), graphite, grindstones, jewelry and metal materials.

  FIG. 2 is an enlarged schematic view of the superabrasive wire saw in FIG. A part of FIG. 2 shows a longitudinal section of the superabrasive wire saw in the longitudinal direction. FIG. 3 is a schematic diagram showing a cross section taken along line III-III in FIG.

  Referring to FIGS. 2 and 3, superabrasive wire saw 10 includes a core wire 11 that extends linearly, a binding material 12 that covers surface 11 a of core wire 11, and a plurality of materials fixed on surface 11 a by binding material 12. And superabrasive grains 13. The superabrasive grains 13 are made of, for example, diamond abrasive grains, and are provided so as to partially protrude from the surface 12 a of the binder 12.

  Superabrasive wire saw 10 has an average diameter D. At this time, three measurement points are selected at arbitrary positions spaced apart in the longitudinal direction of the superabrasive wire saw 10, and the diameter of the superabrasive wire saw 10 is measured in three directions at each of these points, for a total of 9 Get two measurements. And the average diameter D of the superabrasive wire saw 10 is calculated | required by calculating the average of the obtained measured value.

  As the core wire 11, for example, any one of a steel wire, a steel wire subjected to copper plating, and a steel wire subjected to brass plating can be used.

As the steel wire, a piano wire that can be easily finished into a very fine wire and has high strength is most preferable. The piano wire can be used as it is, but in order to facilitate storage and improve the adhesion of the resin bond and increase the holding power of the superabrasive grains, the piano wire has a surface such as copper plating or brass plating. It is preferable to perform the treatment.

  As a core wire of other materials, a single wire or a stranded wire of any one of carbon fiber, aramid fiber, boron fiber, and glass fiber can be used. Alternatively, a stranded wire obtained by mixing two or more kinds of carbon fibers, aramid fibers, boron fibers, and glass fibers can be used. Furthermore, it is also possible to use a stranded wire obtained by adding a steel wire to these stranded wires as a core wire.

  When the average diameter of the superabrasive grains 13 is d2, it is preferable that the average diameters d1 and d2 of the core wire 11 and the superabrasive grains 13 satisfy the relationship 0.02 <d2 / d1 <0.5.

  Resin bond, electrodeposition, metal bond or vitrified bond can be used as the binder 12. Various binders such as a composite bond of a resin bond and a metal bond and a composite bond of a resin bond and a vitrified bond can also be used as the binder 12. It should be noted that the effect of this embodiment is particularly noticeable when a resin bond or a composite bond mainly composed of a resin bond is used.

  Resins that can be used as resin bonds include alkyd resin, phenol resin, formalin resin, polyurethane resin, polyester resin, polyimide resin, epoxy resin, melamine resin, urea from the viewpoint of elastic modulus, softening temperature, moldability, and physical properties. Resins, unsaturated polyester resins, acrylic resins, polyester imide resins, polyamide imide resins, polyester urethane resins, bismaleimide resins, bismaleimide triazine resins, cyanate ester resins, polyether imides, polyparabanic acids, aromatic polyamides and the like are preferable.

  Electrodeposition refers to the case where the bonding material 12 is formed on the surface 11a of the core wire 11 by electrodeposition. For example, nickel (Ni) plating is formed on the surface 11a as the bonding material 12. Further, when a metal bond is used as the binder 12, an appropriate metal powder and superabrasive grains 13 are mixed and the mixed powder is baked onto the surface 11 a of the core wire 11.

  FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. In FIG. 4, only a part of the superabrasive wire saw 10 actually wound on the reel 1 is schematically shown. Referring to FIG. 4, the reel 1 includes a drum portion 2 and a flange portion 5 that rises in a direction perpendicular to both ends of the drum portion 2. One end 3 and the other end 4 are defined at positions where the drum portion 2 and the flange portion 5 intersect.

  First, the superabrasive wire saw 10 is wound around the drum portion 2 at a pitch P from one end 3 to the other end 4 (first layer superabrasive wire saw 101). After the superabrasive wire saw of the first layer is wound up to the other end 4, the superabrasive wire saw 10 is pitched from the top of the already wound superabrasive wire saw toward the other end 4 from the other end 4. Wrapped with P (second layer superabrasive wire saw 102). Furthermore, the superabrasive wire saw 10 has one end 3 and the other end in the third layer from the one end 3 to the other end 4 and in the fourth layer from the other end 4 to the one end 3. 4 is wound in multiple layers at a pitch P while reciprocating between the two.

  Moreover, based on the winding tension T of the superabrasive wire saw 10 measured by a tension meter, an appropriate rotation speed may be instructed from a control unit (not shown) to the motor. In this case, it is preferable that the rotation speed of the motor 22 is instructed from a control unit (not shown) so that the winding tension T is 3N to 40N. Thereby, it can prevent that the superabrasive wire saw 10 once wound loosens. At the same time, it is possible to prevent the wound superabrasive wire saws 10 from biting into each other and damaging the bonding material 12.

  The reel 1 for winding the superabrasive wire saw includes a drum portion 2 extending in the direction of the winding shaft 80 and a flange portion 5 extending from the drum portion 2 in the outer peripheral direction. The drum portion 2 and the flange portion 5 are: It is formed of an integral body made of an aluminum alloy casting. Since the drum portion 2 and the flange portion 5 are formed of an integral body made of an aluminum alloy casting, the reel 1 is light, the unbalance can be easily reduced, and the effect of reducing vibration during rotation can be obtained. Further, it is possible to provide the reel 1 that can obtain an energy saving effect in terms of power during rotation and can be manufactured at low cost. Preferably, the composition of the aluminum alloy is 85 to 98 mass% for Al, 0.5 mass% or less for Si, 0.25 mass% or less for Cu, and 2 to 10 mass% for Mg. Preferably, the hardness of the aluminum alloy is 40 or more in terms of Brinell hardness. Preferably, the breaking elongation of the aluminum alloy is 5% or more. Preferably, the superabrasive wire saw 10 has a core wire having a diameter of 0.03 mm to 0.5 mm. Preferably, the winding tension of the superabrasive wire saw 10 is 3N to 40N. Preferably, the winding pitch of the superabrasive wire saw 10 is 0.05 mm to 3.0 mm, and the number of winding stages is two or more. Preferably, the reel 1 is for one-use use. Preferably, the surface roughness of the drum portion 2 and the flange portion 5 that are in contact with the superabrasive wire saw 10 is Ra 3.2 μm or less.

  FIG. 5 is a perspective view showing a superabrasive wire saw cutting apparatus according to an embodiment of the present invention. Referring to FIG. 5, superabrasive wire saw cutting apparatus 51 includes a superabrasive wire saw supply unit 57 that feeds and collects superabrasive wire saw 10 with workpiece 55. The superabrasive wire saw supply unit 57 is provided with a reel 1 around which the superabrasive wire saw 10 is wound using the superabrasive wire saw winding structure according to the first or second embodiment. Two reels 1 are arranged on both sides of the workpiece 55, and are respectively attached to the rotation shaft of the motor.

  The superabrasive wire saw cutting device 51 further includes a plurality of guide rollers 52 and 53 for guiding the superabrasive wire saw 10 and two main rollers located below the workpiece 55 and arranged at a predetermined interval. 56 and two cutting fluid nozzles 54 provided in the vicinity of the main roller 56. Grooves are provided on the outer peripheral surface of the main roller 56 in accordance with the cut dimensions of the workpiece 55. A superabrasive wire saw 10 having both ends wound around two reels 1 is stretched between two main rollers 56 while being guided by the grooves. The guide roller 52 is provided so as to be able to reciprocate in a predetermined direction.

  When the workpiece 55 is cut using the superabrasive wire saw cutting device 51, the motor to which the reel 1 is connected is reversed in the forward direction, and the superabrasive wire saw 10 is reciprocated between the two reels 1. At this time, the guide roller 52 may reciprocate similarly to the traverser 24 shown in FIG. Thereby, even during the cutting process using the superabrasive wire saw cutting device 51, the superabrasive wire saw 10 is wound around the reel 1 at a predetermined pitch P, and the same effects as those described in the first or second embodiment are obtained. Can be played.

  Subsequently, the workpiece 55 is pressed toward a large number of superabrasive wire saws 10 that move between the two main rollers 56. Thereby, the workpiece 55 can be cut into a large number of sheets. At this time, the cutting fluid is supplied from the cutting fluid nozzle 54 to the groove formed on the outer peripheral surface of the main roller 56 and the workpiece 55. This cutting fluid plays a role of reducing friction during cutting and promoting cooling. When the guide roller 52 is reciprocated so that the superabrasive wire saw 10 is wound at a predetermined pitch P, the superabrasive wire saw 10 is wound around the reel 1 while the superabrasive wire saw 10 is wound around the reel 1. The cutting fluid supplied at the time of cutting is interposed in the gap. For this reason, it is thought that the above-mentioned effect by the cutting fluid can be obtained particularly effectively.

Example 1
An aluminum alloy casting reel for the superabrasive wire saw of Example 1 of the present invention as described below was manufactured, and the effect of the present invention was confirmed by experiments.

  The composition of the aluminum alloy casting used in the reel made of the aluminum alloy casting of Example 1 is mass%, Si is 0.15%, Cu is 0.05%, Mg is 5%, and the balance is Al and a small amount of impurities (Zn Fe, Mn, Ni, Ti, Pb, Sn, Cr, etc.). The aluminum alloy casting had a Brinell hardness (HBW) of 45 and an elongation of 10%. In this specification, “elongation” means elongation at break. The surface of the aluminum alloy casting reel was cut by a cutting tool, and the surface roughness of the drum portion 2 and the flange portion 5 in contact with the superabrasive wire saw was Ra 0.4 μm. The dimensions of the reel made of cast aluminum alloy are 110 mm for the outer diameter (diameter) D1 of the body part (drum part 2), 250 mm for the length L1, and 190 mm for the outer diameter (diameter) D2 of the flange part (flange part 5). T1 was 20 mm.

  The superabrasive wire saw used for winding is a resin-bonded superabrasive wire saw in which diamond abrasive grains having an average particle diameter of 5 μm are fixed to the surface of a piano wire having a diameter of 0.03 mm with a phenol-based resin bond. ) D was 0.041 mm.

  This resin-bonded superabrasive wire saw was wound around the reel with a pitch P of 0.05 mm and a winding tension of 3 N to a total length of 10 km.

  In this way, a silicon ingot slicing experiment was conducted by attaching a reel wound with a resin bond superabrasive wire saw 10 km to a wire saw cutting machine, and the silicon ingot was sliced. Good surface roughness was also obtained for the cut surface.

  (Examples 2 to 20)

  In Examples 2 to 20, the superabrasive wire saw shown in Tables 1 and 2 was wound around a reel. The dimensions of the reel are the same as those in Example 1, and the aluminum alloys constituting the reel are those shown in Tables 1 and 2.

  When a reel in which these superabrasive wire saws were wound was attached to a wire saw cutting machine and a silicon ingot slicing experiment was conducted, there was no vibration of the wire saw cutting machine, good sharpness was exhibited, and the silicon ingot cutting surface was also Good surface roughness was obtained.

  It should be understood that the embodiments and examples disclosed herein are illustrative and non-restrictive in every respect. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  The reel of the present invention can be used for winding various types of superabrasive wire saws.

1 reel, 2 drum part, 3 one end, 4 other end, 5 flange part, 10 superabrasive wire saw, 11 core wire, 11a surface, 12 binder, 13 superabrasive grain, 51 superabrasive wire saw cutting device.

Claims (9)

A super-abrasive wire saw winding reel,
A drum portion extending in the winding axis direction;
A flange portion extending in the outer peripheral direction from the drum portion,
The reel for winding a superabrasive wire saw, wherein the drum portion and the flange portion are formed of an integral body made of an aluminum alloy casting.   The composition of the aluminum alloy according to claim 1, wherein Al is 85 to 98 mass%, Si is 0.5 mass% or less, Cu is 0.25 mass% or less, and Mg is 2 to 10 mass%. Reel for winding abrasive wire saw.   3. The superabrasive wire saw winding reel according to claim 1, wherein the aluminum alloy has a Brinell hardness of 40 or more.   The superabrasive wire saw winding reel according to any one of claims 1 to 3, wherein the breaking elongation of the aluminum alloy is 5% or more.   The superabrasive wire saw is a reel for winding a superabrasive wire saw according to any one of claims 1 to 4, wherein the superabrasive wire saw has a core wire having a diameter of 0.03 mm to 0.5 mm.   The superabrasive wire saw winding reel according to any one of claims 1 to 5, wherein a winding tension of the superabrasive wire saw is 3N to 40N.   The superabrasive wire saw winding reel according to any one of claims 1 to 6, wherein the winding pitch of the superabrasive wire saw is 0.05 mm to 3.0 mm, and the number of winding stages is two or more.   The reel for winding a superabrasive wire saw according to any one of claims 1 to 7, which is for one-use use.   The reel for winding a superabrasive wire saw according to any one of claims 1 to 8, wherein the surface roughness of the drum portion and the flange portion in contact with the superabrasive wire saw is Ra 3.2 µm or less.

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