KR102164683B1 - Method for manufacturing wire saw using foam coating process and wire saw manufactured thereby - Google Patents

Abstract

The present invention comprises the steps of: (a) forming a foam layer on the upper layer of the coating liquid by foaming a coating liquid containing abrasive powder; (b) forming a foam coating layer on the surface of the wire by introducing a wire such that the outer peripheral surface is in contact with the foam layer; And (c) curing the wire on which the foam coating layer is formed in step (b) to prepare a wire saw to which the abrasive powder is fixed.
According to the method of manufacturing a wire saw according to the present invention, abrasive powder particles are uniformly formed on the surface by using a simple foam coating method in which a wire is introduced so that the surface is in contact with the foam layer formed with a coating solution containing abrasive powder particles. And, the coated abrasive powder particles are not easily peeled off the wire, so that a wire saw having excellent long-term durability can be manufactured.

Description

Method for manufacturing wire saw using foam coating process and wire saw manufactured thereby {Method for manufacturing wire saw using foam coating process and wire saw manufactured thereby}

The present invention relates to a method of manufacturing a wire saw by using a foam coating process in which a wire is introduced into a foam layer containing abrasive powder to form a foam coating layer on the surface of the wire, and to a wire saw manufactured thereby.

In general, a wire saw is a cutting tool used to cut an object, and not only can cut the object to be cut by contacting the surface in a vertical or horizontal direction, but also the outer peripheral surface of the wire saw is wrapped around the surface. It has been introduced and used in various industrial fields because it can be wound around the outer circumference of the object to be cut so that it can be cut and contacted in a rotating manner to cut the object to be cut.

The wire saw can be largely divided into abrasive wire saw and fixed wire saw according to the method of introducing abrasive material between the wire and the cutting object, and the abrasive wire saw between the heat of the wire and the object to be cut, silicon carbide powder, diamond powder By supplying a cutting material containing an abrasive (or abrasive powder) and oil, which is used as a method of cutting the object to be cut by the cutting action of the abrasive particles, and coating a polymer resin with a fixed wire saw, or by a plating method It is used for direct cutting without separately supplying the abrasive and oil to the individual to be cut by fixing the abrasive to the wire by plating.

Specifically, the wire saw as described above is used for cutting construction materials such as stone, concrete, H-beam, etc., or for precisely cutting silicon single crystal, sapphire, and polycrystalline material for solar cells, and in particular, silicon single crystal, A fixed diamond wire saw is manufactured and used for cutting high hardness units to be cut such as sapphire and polycrystalline materials for solar cells, or for precise cutting of semiconductor wafers.

The existing fixed diamond wire saw, a resin bond wire saw fixed using an adhesive resin such as a polishing electrodeposition wire saw, resin bond, and thermosetting resin fixed with diamond powder by electroplating, a metal layer by reversal, etc. A typical example is a metal layer wire saw introduced and fixed.

However, since the resin bond wire saw has a low strength of the adhesive, the life of the wire saw is short, and it is difficult to uniformly introduce diamond into the wire saw.In the case of the metal layer wire saw, the metal contained in the crucible is melted to make the wire Since the process of introducing a metal layer is included in the molten metal, it is difficult and complicated to handle the molten metal, and the manufacturing cost is greatly increased. Therefore, a study on a method that can compensate for such disadvantages is required.

(Document 01) Korean Patent Publication No. 10-2017-0122999 (Announcement date: 2017.11.07.) (Document 02) Korean Patent Registration No. 10-1127447 (Announcement date: 2012.03.23.) (Document 03) Japanese Patent Registration No. 4939635 (Publication date: 2011.10.06.)

The inventors of the present invention were researching a method for uniformly coating abrasive powder particles on the surface of the wire in order to manufacture a wire saw, while making the wire so that the surface is in contact with a foam layer formed with a coating solution containing abrasive powder. Using the introduced foam coating method, it was confirmed that the abrasive powder particles can be uniformly coated on the surface of the wire, and the coated abrasive powder particles are not easily peeled off the wire, so that a wire saw having excellent long-term durability can be manufactured. The present invention has been completed.

Accordingly, the present invention is to provide technical details of a method for manufacturing a wire saw by introducing a foam coating method for forming a foam coating layer on the surface of the wire.

In order to achieve the technical problem as described above, the present invention includes the steps of: (a) forming a foam layer on the upper layer of the coating solution by foaming a coating solution containing abrasive powder; (b) forming a foam coating layer on the surface of the wire by introducing a wire such that the outer peripheral surface is in contact with the foam layer; And (c) curing the wire on which the foam coating layer is formed in step (b) to prepare a wire saw to which the abrasive powder is fixed.

In addition, the abrasive powder is diamond powder, alumina powder, silicon carbide powder, tungsten powder, tungsten carbide powder, titanium powder ), titanium carbide powder, boron nitride powder, and at least one selected from the group consisting of cemented carbide powder.

The coating solution may be a resin bond mixture comprising the abrasive powder and a polymer resin, or plating comprising the abrasive powder and nickel sulfate, nickel chloride, and boric acid Mixed solutions can also be used.

In addition, the foam layer may have a plurality of pores having an average particle size of 1 to 2000 μm, and the abrasive powder may have an average particle size of 0.1 to 200 μm.

In addition, the present invention provides a wire saw manufactured by the method described above.

According to the method of manufacturing a wire saw according to the present invention, by using a simple foam coating method in which a wire is introduced so that the surface is brought into contact with the foam layer formed with a coating solution containing abrasive powder, abrasive powder particles are uniformly coated on the surface. , The coated abrasive powder particles are not easily peeled off the wire, so that a wire saw having excellent long-term durability can be manufactured.

The abrasive powder particles of the wire saw manufactured by the above method are strongly adhered to the surface of the wire, so that the loss of raw materials is low and the durability is very excellent, as well as the precision cutting of the object to be cut is possible, as a cutting tool in various industrial fields. It can be used easily.

1 is a process chart schematically showing a method of manufacturing a wire saw according to the present invention.
Figure 2 is a process diagram showing a method of manufacturing a wire saw according to the present invention.
3 is a conceptual diagram schematically showing (a) a wire saw manufactured using a single wire and (b) a wire saw manufactured using a steel wire according to a preferred embodiment of the present invention.
4 is a conceptual diagram schematically showing an example of a foam coating device used in the manufacturing method of a wire saw according to the present invention.
5 is an electron microscope image of a wire saw manufactured by a method according to an embodiment.
6 is an SEM image of a wire saw manufactured by a method according to a comparative example.

Hereinafter, the present invention will be described in detail.

1 is a conceptual diagram schematically showing a manufacturing method of a wire saw according to the present invention, Figure 2 is a process diagram showing each step of the manufacturing method of the wire saw according to the present invention.

Referring to FIGS. 1 and 2, the method of manufacturing a wire saw according to the present invention includes the steps of: (a) forming a foam layer on the upper layer of the coating solution by foaming a coating solution containing abrasive powder (S100); (b) forming a foam coating layer on the surface of the wire by introducing a wire such that the outer peripheral surface is in contact with the foam layer (S200); And (c) curing the wire on which the foam coating layer is formed in step (b) to prepare a wire saw to which the abrasive powder is fixed (S300).

The step (a) is a step (S100) of forming a foam layer on the upper layer of the coating solution by foaming a coating solution containing abrasive powder.

In this step, a foam layer is formed by forming a large amount of air bubbles in the coating solution, and a wire saw having abrasive powder particles uniformly coated can be prepared by introducing a wire into the foam layer in a step to be described later.

The foam layer is in a state in which abrasive powder particles are suspended on the surface of the foam droplet, and when the wire is introduced into the foam layer in this state, the foam droplets are uniformly coated on the surface of the wire, and the abrasive powder floating on the foam droplets The particles are coated on the wire, and by introducing the wire to the foam layer in this way, it is possible to manufacture a wire saw uniformly coated with abrasive powder particles in a short time.

The foam layer may form a foam layer on the upper surface of the coating liquid by supplying the coating liquid to a coating bath equipped with a stirring means and stirring the supplied coating liquid, or supplying the coating liquid to the coating bath through a bubble generating device.

The abrasive powder exhibits a cutting force of cutting by grinding the object to be cut in contact with the wire saw when cutting the object to be cut using a wire saw, and an abrasive powder material that provides excellent cutting power can be used.

For example, the abrasive powder is diamond powder, alumina powder, silicon carbide powder, tungsten powder, tungsten carbide powder, titanium powder. powder), titanium carbide powder, cemented carbide powder, cubic boron nitride powder, or a mixture thereof, preferably diamond powder exhibiting excellent cutting power is introduced. Can be used.

In addition, the abrasive powder may be used having an average particle size of 0.1 to 200 μm so that it provides excellent cutting power by friction with the object to be cut and can be firmly fixedly bonded to the wire used as the base material. If the average particle size is less than 0.1 µm, the amount of abrasive powder particles (AP) introduced to the surface of the wire can be greatly increased, but the abrasion resistance of the wire, which is the base material, decreases, making it difficult to use the manufactured wire saw for a long time. In addition, when the average particle size of the abrasive powder exceeds 200 µm, the abrasive powder may have a coarse particle size, and thus the adhesion to the wire may be reduced, and thus the wire may be easily removed from the saw, resulting in a problem of lowering the cutting force.

Preferably, diamond powder may be used as the abrasive powder, and those having an average particle size of 5 to 20 μm may be used.

In this step, it is possible to use a variety of known coating liquids commonly used to introduce the abrasive powder into the wire.

As an example, the coating solution uses a plating solution such as Watt's plating solution or nickel sulfamate, which can produce a durable wire saw by strongly fixing abrasive powder such as diamond powder, and the plating A plating mixed solution in which the solution is mixed with abrasive powder can be used.

As another example, the coating solution may be a resin bond mixture including a polymer resin such as a polyurethane resin, an ultraviolet curing resin, an acrylic resin, and an abrasive powder.

Preferably, as the coating solution, a plating solution including nickel sulfate, nickel chloride, and boric acid and a plating mixed solution including abrasive grains may be used.

Specifically, the plating solution may contain 50 to 200 parts by weight of nickel sulfate, 50 to 150 parts by weight of nickel chloride, and 10 to 100 parts by weight of boric acid, and a hydrogen ion concentration of 1.5 to 5.2 may be used. More preferably, the plating solution may include 100 parts by weight of nickel sulfate, 80 parts by weight of nickel chloride, and 20 parts by weight of boric acid.

The plating solution as described above may be uniformly mixed with the abrasive powder and used as a coating solution. To this end, by introducing the plating mixed solution having the above composition into a coating bath equipped with an electrode so that the foam generating means and current can be generated, a foam layer can be formed on the upper layer of the coating solution, and the precipitation of the abrasive powder is generated. It may be configured to continuously stir the coating solution so that one foam layer is not formed.

In particular, the coating solution may contain abrasive powder in a ratio of 1 to 30 parts by weight based on 100 parts by weight of the plating solution, and when the amount of the abrasive powder mixed in 100 parts by weight of the coating solution is less than 1 part by weight, the abrasive particles introduced into the wire When the amount of powder particles is insignificant, the cutting power of the manufactured wire saw is insignificant, and when the mixing amount of the abrasive powder exceeds 30 parts by weight, the amount of abrasive powder particles introduced into the wire decreases, and the flexibility of the manufactured wire saw decreases. Due to poor adhesion of the powder particles, there may be a problem that the abrasive powder particles are easily removed from the wire saw.

In addition, the coating liquid may be configured to additionally contain a stress reliever such as triethanolamine, monoethanolamine, diethanolamine, etc., which improve internal stress so that the abrasive powder particles can be uniformly coated, and sodium lauryl sulfate ) Can be configured to additionally include a humectant such as.

In addition, the coating solution adds auxiliary plating powder particles such as carbon nanotubes, nickel, zinc, iron, silver, cobalt, platinum, copper, chromium, tungsten, or a mixture thereof so that the abrasive powder particles can be strongly bonded to the wire. The auxiliary adhesive particles as described above may be used by mixing with the abrasive powder particles in a weight ratio of 20:1 to 3:1.

In addition, the coating solution may further include an additive such as a foaming agent, a thickener, or a mixture thereof, and the foaming agent and the thickener may be used by selecting a material having excellent compatibility with the coating solution.

Further, in this step, the temperature of the coating solution can be set to be 30 to 60° C., and bubbles on the surface of the wire through an electrolytic plating method in which a current is formed to have a current density of 5 to 300 mA/cm ² through the electrode. It is possible to form a coating layer.

Meanwhile, in this step, a foam layer may be formed using a foam coating apparatus having various structures capable of forming a foam coating layer on the wire by generating foam, and such a foam coating apparatus will be described in more detail below.

The step (b) is a step (S200) of forming a foam coating layer on the surface of the wire by introducing a wire such that the outer peripheral surface is in contact with the foam layer.

In this step, a large amount of air bubbles are formed in the coating solution so that the outer circumferential surface of the wire is in contact with the foam layer in which the abrasive powder particles are floating on the surface, and the foam of the foam layer adheres to the outer circumferential surface of the wire. By allowing the particles to be introduced, the abrasive powder particles and the coating solution are coated on the surface of the wire to attach the abrasive powder particles to the wire.

As described above, in the case of manufacturing a wire saw through the method of introducing a wire into the foam layer, it is possible to uniformly coat the abrasive powder particles on the wire, and the abrasive powder particles, which are fine particles, can be easily coated on a wire with a small diameter in a short time. You can do it.

The wire is a base material for manufacturing a wire saw, and in order to use the manufactured wire saw for the purpose of cutting an object to be cut, one manufactured using a material having high tensile strength may be used, and the wire is a high carbon steel , A steel alloy used as a piano wire, tungsten, aluminum, stainless steel, tungsten alloy, a steel wire made of a material containing copper, etc. can be used, and a single wire or a steel wire made by twisting several single wires can be used. A steel wire having a structure with a silver cross section of 1×7 (6 covered wires twisted on one central core line), 3×9, 7×7, or 7×19 may be used.

In addition, the wire may use all of the various types of wires used to manufacture the wire saw, and the wire is formed with an uneven structure on the surface so that the foam coating layer can be easily introduced on the surface, or by pretreatment. The wire may be coated with brass, nickel tin or copper on the surface, or may be coated with solder or the like.

In particular, in the method of manufacturing a wire saw according to the present invention, through the process of introducing the wire into the foam layer, fine bubbles are introduced to the surface of the wire to fix the abrasive powder particles, so that even a wire having a very small diameter can be easily abrasive powder Particles can be fixed.

Therefore, in the method of manufacturing a wire saw according to the present invention, the wire is not largely limited to the diameter, but preferably 0.01 to 10 mm may be used, and more preferably 0.1 to 1 mm may be used.

In addition, the foam layer may have a plurality of pores having an average particle size of 1 to 2000 μm, and if the pore size formed in the foam layer is less than 1 μm, there may be a problem that the coating amount of the abrasive powder particles is excessive. In addition, when the size of the pores formed in the foam layer exceeds 2000 µm, the coating amount of the abrasive powder particles may be insignificant.

In addition, the abrasive powder may be used having an average particle size of 0.1 to 200 μm, and when the average particle size of the abrasive powder particles is less than 0.1 μm, a slight problem of cutting force may occur, and when it exceeds 200 μm, the abrasive powder There may be a problem that the particles are easily peeled off.

In particular, before the wire is introduced into the foam layer to attach the abrasive powder particles, a pretreated wire may be used to remove impurities such as organic matter remaining on the surface and to improve the adhesion between the abrasive powder particles and the coating liquid. The pretreatment may remove organic matters through a degreasing process, etc., and in order to remove oxides on the wire surface and activate a fine uneven structure on the surface of the wire, a pickling treatment process of washing with an aqueous acid solution is performed. It can be used, and due to the degreasing process and the uneven structure as described above, the abrasive powder particles can increase the adhesion to the surface of the wire.

In this step as described above, a foam coating layer may be formed on the surface of the wire by forming the wire as described above using the above-described coating solution so that the outer circumferential surface of the wire is in contact with the foam layer on the top, and the wire is transferred.

At this time, the quality of the manufactured wire saw is an important factor in determining the quality of the wire saw, and how uniformly and largely the wire saw can fix the abrasive powder particles.In this step, after supplying the wire to the foam layer, By allowing the wire to be transferred at a speed of 10 to 100 m/min in the foam layer, a foam coating layer can be formed on the surface of the wire, and preferably, the foam coating layer is transferred at a speed of 30 to 60 m/min. Can be formed on the surface.

In the step (c), as a step of curing the wire on which the foam coating layer is formed in the step (b) to prepare a wire saw to which the abrasive powder is fixed, the foam coating layer is cured and fixed between the coating layer and the coating layer on the surface of the wire. It is possible to prepare a wire saw including the abrasive powder particles.

In this step, a wire saw can be manufactured using an optional method according to the type of the coating mixture solution used.

As an example, when a plating mixed solution is used as the coating solution and coated by electrolytic plating in a coating bath in which an electric current is formed, abrasive powder particles are strongly bonded to the surface of the wire by electric current in the electrolytic coating bath described above, By curing the coating liquid contained in the remaining foam coating layer at room temperature, a wire saw including abrasive powder particles fixed between the wire surface coating layer and the coating layer can be prepared.

As another example, in the case of coating in a coating bath in which no current is formed by the electroless plating method, an electroless plating method in which a wire is passed through a foam layer, and then the wire is introduced into a reduction vessel supplied with a reducing gas and subjected to reduction treatment. Through the curing of the coating solution contained in the foam coating layer can be formed to form a plating coating layer capable of firmly bonding the wire and the abrasive powder particles.

As another example, when the foam coating layer is formed using a resin bond mixture, after the foam coating layer is formed, it is cured through a method such as heat treatment or ultraviolet irradiation to prepare a wire saw with abrasive powder fixed on the surface. can do.

According to a preferred embodiment of the present invention, in this step, a plating solution containing 100 parts by weight of nickel sulfate, 80 parts by weight of nickel chloride, and 20 parts by weight of boric acid is used, and the average particle size is 5 parts by weight of the plating solution. A mixed plating solution obtained by mixing 10 parts by weight of abrasive powder having an average particle size of 10 to 200 μm is used as a coating solution, and the coating solution is supplied to a coating bath equipped with a stirring means and stirred to form excess air bubbles. After allowing bubbles to form, a wire having a diameter of 0.1 to 10 mm is passed through the foam layer in a state set to be transferred at a speed of 30 to 60 m/min, and a current density of 50 to 300 mA/cm ² The abrasive powder particles can be fixed to the surface of the wire by allowing bubbles to adhere to the surface by an electrolytic plating method that supplies current as much as possible.

At this time, the coating solution is based on 1 L of plating solution, 1 L of plating solution containing 200 g/L of nickel sulfate, 160 g/L of nickel chloride, and 40 g/L of boric acid, and diamond powder having an average particle size of 5 to 20 μm. 10 to 300 g/L is mixed to prepare a plating mixed solution, and then the prepared plating mixed solution is supplied to the coating bath through a bubble generating bath to generate a large amount of air bubbles, and the average particle size is 10 to 200 µm. Phosphorus is formed on the foam layer where bubbles are formed, and the coating bath is heated so that the temperature of the coating mixture is 45 to 50 °C, and current is supplied through the electrode to a current density of 50 to 300 mA/cm ² . And, it is possible to prepare a wire saw in which abrasive powder particles are fixed on the surface of the wire by introducing a wire into the foam layer.

The wire sawing coating layer prepared by the above method is formed to a thickness of 1 to 20 µm on the surface of the base material, and abrasive powder particles having an average particle size of 5 to 20 µm are uniformly introduced to show excellent cutting power. , It can exhibit a property that does not peel off easily from the wire.

Further, in this step, to further include the step of preparing a wire saw in a state in which the abrasive powder particles are firmly fixed to the wire by the coating layer in the same manner as described above, and then forming a protective coating layer on the surface of the manufactured wire saw. Configurable.

The protective coating layer can be formed using an elastomer material such as polyurethane resin, whereby when the endless wire saw is wound on a roller, it is possible to prevent the separation of the abrasive powder particles formed on the wire saw, and it is generated during winding. Abrasion and loss of abrasive powder particles can be prevented, whereby the wire saw is wound and the wire saw manufactured in an endless type can be wound and distributed on a roller or the like.

The wire saw manufactured by the above method, the base material of the wire 100, the coating layer 200 adhered to the outer circumferential surface of the wire, and the abrasive powder particles 210 attached and fixed to the wire through the coating layer 200 It has a structure including, and as shown in FIG. 3(a), a wire saw formed using a single wire and a wire saw formed using a steel wire, as shown in FIG. 3(b). You will be able to.

On the other hand, in the manufacturing method of the wire saw according to the present invention, in order to form a foam layer on the upper surface of the coating liquid using the coating liquid, and to form a foam coating layer by introducing the wire into the foam layer, various types of conventional coating devices are used. A foam layer can be formed.

4 is a conceptual diagram schematically showing an example of a foam coating device 500 used in the method for manufacturing a wire saw according to the present invention.

Referring to FIG. 4, the foam coating device 500 is pipe-connected by a coating liquid supply unit (not shown) and a first inlet pipe 511 for mixing and supplying abrasive powder and coating liquid, and air to generate foam. The air supply unit (not shown) and the second inlet pipe 513 supplying the pipe are connected to each other, and a receiving space for manufacturing a mixed coating solution by receiving and mixing abrasive powder, coating solution and air is provided, and a discharge passage is provided on one side. A coating liquid mixing tank 510 for discharging the formed and prepared mixed coating liquid, the coating liquid mixing tank 510 and the third inlet pipe 531 are connected through a pipe, and a micrometer (㎛) or nanometer (nm) inside A bubble generating space in which bubbles of the size are generated is formed to generate bubbles by receiving the mixed coating solution, and an outlet is formed on one side of the upper side to discharge the mixed coating solution in which bubbles are formed. The mixed coating liquid with foam is supplied from the generating tank 530 to accommodate the coating liquid with a foam layer formed thereon, and an electrode is provided inside to generate electric current, and a stirring means 570 is provided therein to It has a structure including a coating bath 550 for continuously stirring the precipitated diamond and generating bubbles.

The coating device 500 having the above structure can generate a large amount of foam on the top of the coating liquid, and is provided with a stirring means for continuously stirring so that the abrasive powder particles are evenly distributed on the surface of the foam and foam is generated. It has a structured structure, by introducing and transporting the wire to the foam layer formed on the upper surface of the coating tank as described above, it is possible to form a foam coating layer so that a uniform amount of abrasive powder particles are coated on the surface of the wire.

In particular, the bubble generating tank 530 provided in the coating device 500 allows the coating liquid to collide therein, and is formed by being cut inward from the outer circumferential surface so that the coating liquid branches and passes through a plurality of pieces while the coating liquid collides while moving. The collision plate 533, which is a plate-shaped structure having a plurality of branching spaces formed through the gaps between the incisions, has a structure in which a plurality of collision plates 533 are provided, and the bubble generator 530 supplies the coating liquid and air. It can generate a large amount of micron or nanometer-sized air bubbles.

In addition, the bubble generating tank 530 discharges the coating liquid from the inner upper end toward the outer side, and the collision plate 531 is formed with an incision having a curved structure inclined from one end to the other end to collect the coating liquid and air. It can be supplied and generate a large amount of micro- or nano-sized air bubbles.

Accordingly, in the foam coating apparatus 500 having the above structure, a foam layer containing a large amount of abrasive powder particles (AP) is formed on the upper surface of the coating tank 550, and the foam layer (bubble) By introducing the wire (W), the outer circumferential surface of the wire (W) is in contact with the foam layer to form a foam coating layer, so that it is possible to manufacture a wire saw (WS) having a structure in which abrasive powder particles (AP) are introduced on the surface, When using the foam coating device as described above, it can be configured to manufacture several wire saws in a single coating process by supplying 6 or more strings of wires at the same time, and by supplying 6 to 12 strings of wires It is desirable to be able to manufacture.

In addition, the stirring means 570 provided in the coating tank can introduce a variety of conventional means for generating bubbles, as an example, the stirring means 570 of the driving means to generate bubbles of a uniform size. Mounted on the rotating shaft can be used, and the stirring means includes an annular structure arranged in a plurality of layers spaced apart at a predetermined interval, and a stirring protrusion formed in a direction perpendicular to the annular structure is provided at a predetermined interval, so that the abrasive powder particles are It prevents sedimentation, and can continuously generate microscopic bubbles of micrometer or nanometer size in the coating liquid.

In the method of manufacturing a wire saw according to the present invention, the foam coating device 500 as described above has been described as an example, but the wire saw is manufactured using various conventional foam coating devices capable of generating bubbles to form a large amount of a foam coating layer. can do.

In addition, the foam coating device 500 as described above may be provided with a rotating means for rotating by receiving power, such as a motor, to unwind a wire wound on a wire supply roller and supply it to the foam coating device 500.

In addition, the foam coating device 500 includes a curing unit provided with an ultraviolet irradiation unit, a heating unit, a reducing agent supply unit, etc. to fix the abrasive powder particles on the surface of the wire by forming and curing the foam coating layer on the wire. After curing the foam coating layer to prepare a wire saw with fixed abrasive powder particles, the wire saw manufactured to manufacture a wire saw in an endless type is wound up so that the wire saw roller can be manufactured. It may have a structure including a recovery unit provided with a roller.

Further, the foam coating device 500 adds a protective coating layer generating unit for applying a polyurethane resin to the surface of the wire saw so as to form a bopo coating layer on the surface of the manufactured wire saw between the recovery unit and the curing unit It can be configured to include, but is not limited thereto.

The foam coating device 500 as described above can be configured to simultaneously supply 6 or more strings of wires to the foam layer to manufacture several wire saws in a single coating process, and supply 6 to 12 strings of wires. It is desirable to be able to manufacture a wire saw.

According to the method of manufacturing a wire saw according to the present invention as described above, by using a foam coating method in which a wire is introduced so that the surface is in contact with a foam layer formed of a coating liquid containing abrasive powder particles, abrasive powder uniformly on the surface The particles are formed and the coated abrasive powder particles are not easily peeled off the wire, so that a wire saw having excellent long-term durability can be manufactured.

The method of manufacturing a wire saw as described above can be configured to simultaneously supply 6 or more strings of wires to the foam layer to manufacture several wire saws in a single coating process, and by supplying 6 to 12 strings of wires. It is desirable to be able to manufacture a wire saw.

In particular, the abrasive powder particles of the wire saw manufactured by the above method are strongly bonded to the surface of the wire, so that the loss of raw materials is small and the durability is very excellent, and precision cutting of the to-be-cut is possible, so it can be used for cutting in various industrial fields. It can be easily used as a tool.

In addition, the present invention provides a wire saw manufactured using the method as described above, and since abrasive powder particles are uniformly coated on the surface of the wire saw, it can be easily used for cutting a sweet substance to be cut.

Hereinafter, the present invention will be described in more detail by way of examples.

The examples presented are only specific examples of the present invention, and are not intended to limit the scope of the present invention.

<Example 1>

1L of a plating solution prepared by mixing 200 g/L of nickel sulfate, 160 g/L of nickel chloride and 40 g/L of boric acid was prepared, and 100 g/L of diamond powder (average particle size 5 to 20) was added to the prepared plating solution. ㎛) was mixed to prepare a plating mixture solution.

The prepared plating mixed solution was introduced into a foam coating device having a shape as shown in FIG. 4, and the mixed coating solution was passed through a tubular bubble generating tank to generate a large amount of air bubbles in the mixed coating solution and supplied to the coating bath. The stirring means provided in the bath was continuously stirred to maintain the foam layer, and 8 strings of wire were supplied to the top to form a foam coating layer on the surface of the wire.

At this time, the coating bath was supplied with current so that a current density of 80 mA/cm ² was formed while the temperature of the mixed coating solution was maintained at 45 to 50°C, and the wire on which the foam coating layer was formed was cured at room temperature to make diamond abrasive grains. A wire saw to which powder particles are fixed was prepared.

In order to check the quality of the manufactured wire saw, a wire saw specimen was supplied to an electron microscope and the distribution of diamond particles formed on the surface of the wire saw was visually checked.

As a result, as shown in FIG. 5, it was confirmed that diamond particles were uniformly coated on the surface of the manufactured wire saw.

100: wire 200: coating layer
210: abrasive powder particle 500: foam coating device
510: coating liquid mixing tank 530: bubble generating tank
550: coating tank 570: stirring means

Claims (7)

(a) forming a foam layer on the upper layer of the coating solution by foaming a coating solution containing abrasive powder;
(b) forming a foam coating layer on the surface of the wire by introducing a wire such that the outer peripheral surface is in contact with the foam layer; And
(c) hardening the wire on which the foam coating layer is formed in step (b) to prepare a wire saw to which the abrasive powder is fixed; including,
The abrasive powder,
The average particle size is 0.1 to 200 μm,
Diamond powder, alumina powder, silicon carbide powder, tungsten powder, tungsten carbide powder, titanium powder, titanium carbide powder ( titanium carbide powder), boron nitride powder (cubic boron nitride powder), and at least one selected from the group consisting of cemented carbide powder,
The foam layer,
A plurality of pores having an average particle size of 1 to 2000 μm are formed, and particles of the abrasive powder are floating on the surface of the pores,
The wire,
It is characterized in that the diameter is 0.01 to 10 mm,
The coating solution is a method of manufacturing a wire saw, characterized in that the resin bond mixture containing the abrasive powder and a polymer resin. delete delete delete delete delete delete

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