JP3808066B2 - Wire saw - Google Patents

Description

  The present invention relates to a wire saw that is used when cutting stone, concrete, building materials, and the like.

  When cutting stone, concrete, building materials, and the like, a wire saw is used in which a large number of cylindrical beads fixed with superabrasive grains are fixed in a rosary shape to a steel wire or the like. Such a wire saw is used for cutting the above-mentioned work material by connecting the ends of the wire into an endless shape and applying a tension to drive the pulley.

  Conventionally, bonding of beads and wires is performed by bonding with rubber or caulking of a sleeve, and the exposed surfaces of the sleeves around the wires and beads are covered with vulcanized rubber. However, the adhesive strength between the outer peripheral surface of the beads and the rubber was weak, causing adhesive breakage during use and water intrusion, generating rust and breaking the wire.

  In addition, if the inner peripheral surface of the bead and the wire are bonded with rubber, a large force is applied to the bead when a wire saw is used, causing a situation where the bead and wire are broken and the bead rotates or the wire breaks. It was. Further, when the beads were fixed to the wire by caulking the sleeve, stress was concentrated on the caulked portion, so that the wire was easily broken at the caulked portion during use of the wire saw.

  Various studies have been made to prevent such damage to the wire saw. For example, in Patent Document 1, the inner surface of a sleeve member and the surface of a wire rope, and at least both end surfaces of the sleeve member and a grinding member are vulcanized and bonded with an adhesive for rubber and metal, and copper, zinc are bonded to the surface of the wire rope. A wire saw using a steel cord that has been drawn and then drawn and diffused at a high temperature is disclosed.

  Patent Document 2 discloses a wire saw in which a cylindrical bead to which superabrasive grains are fixed is fixed to a wire. At least a surface of the bead contacting with rubber is subjected to brass plating, and the bead is fixed to the wire with rubber. The wire saw characterized by comprising is disclosed.

  Further, in Patent Document 3, annular grooves are formed at both ends located outside the metal layer formed on the outer peripheral surface of the cylindrical base metal, and a constant is provided at the center where the metal layer is formed. Through holes are formed at intervals, the beads are arranged at regular intervals, and the synthetic resin is extruded into a mold in which the wires are inserted through the center holes of the plurality of base metals of the plurality of beads. There is disclosed a wire saw provided with a synthetic resin layer that is formed by connecting a plurality of beads and wires integrally with flexibility.

  However, even in such a wire saw, the strength is completely different between the metal grinding member and rubber, and the load is concentrated on the end surface of the grinding member that bends most, so that the wire saw is bent between the grinding member and the rubber sleeve. Repeated fatigue causes cracks in the rubber. Further, since the load applied to the grinding member is held only by the strength of the rubber vulcanized on the inner surface of the sleeve member, the holding force is weak for a large load applied during use, and loosening of the beads and idle rotation occur. This is because the strength of the holding force of only the rubber on the inner surface of the beads is insufficient.

  In Patent Document 4, a plurality of diamond beads are fixed at a predetermined interval on a steel cord coated with rubber or resin in advance, and a flexible material such as resin or rubber is used as a spacer between the diamond beads. Disclosed is a wire saw in which a diamond bead metal core is fixed to the steel cord by caulking, and a diamond bead metal core is fixed to the steel cord by caulking. A wire saw in which a coil spring is disposed as a spacer between diamond beads is disclosed.

  However, even with this wire saw, since the strength is different between the metal grinding member and the rubber, it is impossible to prevent the occurrence of cracks due to the concentration of the load on the end surface of the grinding member that is most bent. In addition, when the beads are fixed to the steel cord by caulking, bending occurs at the end of the metal core of the beads, and the steel cord causes fatigue failure. Further, repeated stress is applied between the bead and the coil spring, and the rubber is cracked.

Japanese Utility Model Publication No. 5-24413 JP-A-9-323214 Japanese Patent No. 2502872 Japanese Patent Laid-Open No. 9-155630

Thus, in the conventional wire saw, as a method of fixing the beads to the wire, it is roughly divided,
(1) Method of bonding or plating beads or wires to adhere to rubber (2) Method of grooving or drilling a bead base and fixing with a covering material (3) ) There is a method of fixing the bead base metal by caulking to the wire.

  However, the method (1) is a method of fixing the bead itself to the wire, and the load is concentrated on the end surface of the bead. In the method (2), a gap is formed between the bead and the spring, and a rubber crack is likely to occur. Furthermore, in the method (3), the load applied to the bead is received by the bead alone, and the wire saw is easily broken from the end of the bead base by caulking the bead base to the wire.

  Thus, all of the conventional wire saws are weak against bending, and it cannot be said that the problems due to this are sufficiently solved.

  The present invention has been made to solve the above-described problems, and suppresses the occurrence of bead rotation and displacement and wire breakage, prevents the coating material from cracking, and has excellent cutting performance. An object of the present invention is to provide a wire saw capable of extending the service life.

  In order to solve the above-described problems, the present invention provides a wire saw formed by alternately arranging beads and springs with superabrasive grains fixed on the surface of a cylindrical base metal on a wire rope and covering them with a flexible material. In the wire saw, the end face of the base metal of the beads and the end face of the spring are bonded.

By bonding the base end surface of the bead and the end surface of the spring into an integrated structure, even if the wire saw is bent, a large load is not concentrated between the bead and the spring, and rotation and displacement due to loosening of the bead are prevented. It does not occur and scattering of beads can be prevented.
In addition, since the beads and the springs are integrated, there is no gap between the beads and the springs, and it is difficult for cracks to occur in the covering material such as rubber, and the wire rusts when water enters the cracks. It is possible to prevent the wire from breaking and breaking.
This bonding may be performed by welding or may be performed using a brazing material.

The present invention is characterized in that the base end face of the beads and the end face of the spring are planarized.
By flattening the base metal end surface and the spring end surface of the beads, the adhesive strength can be increased when the base metal end surface of the beads and the spring end surface are bonded to form an integral structure.

In the present invention, when the bonding is performed with a brazing material, the bonding is performed with a low-temperature brazing material mainly composed of silver.
When a high temperature is applied to the superabrasive layer formed on the bead base, the bond material holding the abrasive will be thermally deteriorated and the holding strength of the abrasive will be reduced. However, by using a low-temperature brazing material mainly composed of silver, the beads and the spring can be bonded without impairing the performance of the superabrasive layer. Here, as a low-temperature brazing material, a composition containing 30% to 60% silver and 20% to 40% copper can be used. By setting the composition within this range, the base metal and the spring have good wettability, the surroundings of the brazing material are good, and bonding can be performed at a low temperature of about 650 ° C. to 780 ° C.
If the silver and copper content is less than the above range, the bonding temperature becomes high and the bond material is deteriorated by heat, which is not preferable. On the other hand, if the content exceeds the above range, the bonding strength decreases, which is not preferable.

The present invention is characterized in that the length of the portion formed by bonding the bead base and the spring is not less than 2 times and not more than 5 times the length of the bead base.
By making the length of the part where the base of the bead and the spring are bonded more than twice the length of the base of the bead, the load applied to the bead is more than twice the load applied to the bead. And the spring can be received by the bonded portion, and load concentration can be effectively prevented. If the length of the part where the base of the bead is bonded to the spring is less than twice the length of the base of the bead, the length of the part formed by bonding is short and the load is concentrated. Cannot be effectively prevented. On the other hand, if the length of the portion where the base of the bead is bonded to the spring exceeds 5 times the length of the base of the bead, the distance between the superabrasive layers becomes far and the curvature of the wire saw becomes small. It is not preferable because it comes into contact with the workpiece and becomes resistance to cutting, and the efficiency is lowered, and the spring is worn and the wire is broken.

The present invention is characterized in that the outer diameter of the spring with respect to the outer diameter of the bead base is 80% or more and 100% or less.
By setting the outer diameter of the spring to be equal to or smaller than the outer diameter of the bead base, the spring does not become a cutting resistance even when the wire saw is bent, and the cutting performance can be maintained well. Further, if the outer diameter of the spring with respect to the outer diameter of the bead base is less than 80%, the contact area with the bead is insufficient, and at the same time, the protection of the wire is weak.

  According to the present invention, the base end face of the bead and the end face of the spring are bonded to form an integral structure, so that even if the wire saw is bent, a large load is not concentrated between the bead and the spring, and the bead is loosened. Rotation and displacement due to the occurrence of the beads can be prevented, and the scattering of the beads can be prevented.

In addition, since the beads and the springs are integrated, there is no gap between the beads and the springs, and it is difficult for cracks to occur in the covering material such as rubber, and the wire rusts when water enters the cracks. It is possible to prevent the wire from breaking and breaking.
As a result, it is possible to realize a wire saw that has excellent cutting performance and can have a long life.

Below, the wire saw of this invention is demonstrated based on the embodiment.
FIG. 1 shows a wire saw according to an embodiment of the present invention.
As shown in FIG. 1, in the wire saw 1, a bead 2 formed by fixing superabrasive grains on the surface of a cylindrical base metal, and a spring 3 formed in a spiral shape on the outer periphery of the wire 4 Covers 5 made of a flexible material such as rubber or resin are provided alternately with respect to the longitudinal direction. The end surface of the base metal of the bead 2 and the end surface of the spring 3 are bonded with a brazing material to form an integral structure.
The length of the portion formed by bonding the base metal of the bead 2 and the spring 3 is formed to be 2 to 5 times the length of the base metal of the bead 2. Here, the length of the portion formed by bonding the base metal of the bead 2 and the spring 3 means the dimension A in FIG. 1, and the length of the base metal of the bead 2 means the dimension B in FIG. Moreover, the outer diameter of the base metal of the bead 2 means the dimension C in FIG. 1, and the outer diameter of the spring 3 means the dimension D in FIG.

In order to confirm the firmness of fixation of the beads 2 in the wire saw having this configuration, a wire saw was produced with the following dimensions and specifications.
Wire saw dimensions φ11 × 6L × 25P
(The outer diameter of the bead base is 8 mm, the length of the bead base is 10 mm, the total length of the bead base and the spring is 25 mm)
Wire φ5.0 steel wire (normal Z twist)
Spring φ7.6 × φ5.2
Coating material SBR rubber Abrasive layer Abrasive grain Synthetic diamond # 40/50 C = 50
Bond material Nickel-based metal bond Table 1 shows a wire saw test product formed by changing the processing method of beads.

In Table 1, the wire bonding process is to apply a synthetic resin adhesive to the wire surface. Further, the adhesive treatment in the bead treatment method means that a synthetic resin adhesive is applied to the inner peripheral surface of the bead, and thereafter, beads and springs are alternately arranged on the wire and filled with rubber. A wire-saw is formed. Accordingly, only the test product 4 has an integral structure in which the base metal end face of the bead and the spring end face are bonded together by the brazing material.
In the test product 4, a brazing material having a composition of Ag 56%, Cu 22%, Sn 5%, Zn 17% was used.
With respect to these test products, an expansion / contraction load was applied to the rubber part of the beads, and the presence or absence of rubber cracks was investigated.
The machine used is an electric drill with specifications of 100 V, 8 A, 760 W, 1100 min ⁻¹ , as shown in FIG. 2, the wire saw 1 is bent and fixed with a fixing jig 11, and an expansion load is applied to the covering material. Thus, the electric drill 12 was attached, the wire saw 1 was rotated, and the crack condition of the coating material was investigated every 30 minutes from the start of the test.

Moreover, the cutting test was done using these test products.
The cutting machine and work material used are as follows.

ワイヤソー長さ：７ｍ
ワイヤソー最小Ｒ：Ｒ２５０

Wire saw length: 7m
Wire saw minimum R: R250

  Table 3 and FIG. 3 show the results of the above investigation of the occurrence of rubber cracks in the rubber part of the beads.

  In the test product 1, the adhesion between the bead and the rubber is poor, and at the same time as the occurrence of the rubber crack, the rubber turn on the bead end surface occurs. Further, in the test product 2, there is no occurrence of rubber turning on the bead end surface, and the rubber crack is less than that in the test product 1 or the test product 3, but it is generated when the test time is longer than 90 minutes. Become. In the test product 3, there is no occurrence of rubber turning on the bead end face, but rubber cracking occurs. On the other hand, in the test product 4, neither rubber turning nor rubber cracking occurred.

Next, the state of bead shift and rubber cracking after the cutting test was investigated. Here, the bead deviation means a state in which the beads are peeled off from the rubber and moved in the traveling direction and the rotating direction.
The survey results are shown in Table 4 and FIG.

  In the test product 1, both rubber cracks and bead deviation were particularly large, and in the test product 2, the occurrence of rubber cracks and bead deviation less than that in the test product 1 was observed. Further, no deviation of the beads occurred in the test product 3, but a rubber crack occurred, and several broken wires were observed at the end of the beads after the test. On the other hand, in the test product 4, neither a rubber crack nor a bead shift occurred.

Next, the results of the cutting performance test are shown in Table 5 and FIG. Here, a cutting test was performed to confirm the heat effect upon bonding the bead and spring of the test product 4. The sharpness was determined by the amount of cutting per unit time (m ² / hr). The D wear amount was compared with the bead outer diameter wear amount after cutting 12 m ² for each test product.

  In Table 5, both the sharpness index and the D wear amount index are expressed as indexes with the numerical value of the test product 2 being 100. The cutting performances of the test product 2 and the test product 4 were equal to each other within 3% of both sharpness and D wear. Thereby, it was confirmed that there is no influence on the cutting performance even when the brazing shown in the present embodiment is performed.

  The present invention can be used as a wire saw used when cutting stone, concrete, building materials, and the like.

It is a figure which shows the wire saw which concerns on embodiment of this invention. It is a layout of a test for investigating the presence or absence of occurrence of rubber cracks by applying an expansion / contraction load to the rubber part of beads. It is a figure which shows the investigation result of the rubber crack generation | occurrence | production with respect to the rubber part of a bead. It is a figure which shows the result of investigating the situation of bead shift and rubber crack generation after a cutting test. It is a figure which shows the result of a cutting performance test.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Wire saw 2 Bead 3 Spring 4 Wire 5 Coating | cover 11 Fixing jig 12 Electric drill

Claims (3)

In a wire saw formed by alternately arranging beads and springs with superabrasive grains fixed on the surface of a cylindrical base metal on a wire rope and covering with a flexible material, the base end surface of the beads and the spring end surface A wire saw characterized in that the base end face of the beads and the end face of the spring are bonded to each other by a low-temperature brazing material having a composition containing 30% to 60% silver and 20% to 40% copper . The length of the portion formed by bonding the above between the base metal of the bead spring, wire saw of claim 1, wherein a is less than 5 times 2 times the length of the bead of the base metal. The wire saw according to claim 1 or 2, wherein an outer diameter of the spring with respect to an outer diameter of the base metal of the beads is 80% or more and 100% or less.

Images