KR20110016237A - A diamond endless wire rope saw and method for preparing the same - Google Patents

Abstract

PURPOSE: A diamond endless wire rope saw and a manufacturing method thereof are provided to reduce the loss of raw materials by reducing the cutting width of a wire rope saw and to precisely cut raw materials. CONSTITUTION: A diamond endless wire rope saw comprises an endless wire rope(100), beads(300), and a synthetic resin(200). A plurality of beads is inserted in the wire rope at regular intervals. Diamond is brazed in the exterior of a shank(320) of a bead. The space between beads is coated with synthetic resin.

Description

Diamond endless wire rope saw and method for preparing the same

The present invention relates to a diamond endless wire rope saw and a method for manufacturing the same, and more particularly to a method for manufacturing a diamond endless wire rope saw having excellent durability such as bonding strength and tensile strength.

Diamond wire saws are generally string-shaped saws, which can provide many advantages over traditional cutting tools. For example, circular saws and the like can cut almost any thickness of structure while the wire saw is limited to a cutting depth below the saw blade radius.

These wire saws are classified into diamond electrodeless wire saws that do not bond both ends of the wires and diamond endless wire saws that bind both ends of the wire and bind in an endless form.

Diamond Electrodeposited Wire This is a structure in which diamond is electrodeposited or attached at regular intervals or irregularly on the surface of a single strand of wire rather than a wire in the form of a wire. As a related art, Patent Document 1 discloses a super-polishing wire saw having a plurality of each coated diamond attached to a wire with an organic binder and manufactured to a diameter of less than 0.5 mm.

However, this diamond electrodeposition wire saw has an advantage of having a diameter of 0.5 mm or less, but because it is a single wire rather than a rope type, a wire saw having a length of at least 5 km is wound in a reel form to unwind and wind it. Due to its weakness and durability, the wire breaks frequently during use and the service life is very short, and the wires rise due to the roughness of the diamond electrodeposited on the wire surface during repeated winding and unwinding of the reel. The burning phenomenon occurs and it is very difficult to adjust the tension of the wire, so that the wire is frequently broken, and the movable equipment is very expensive.

On the other hand, the diamond endless wire rope saw, as shown in Figure 1, cylindrical with a synthetic resin, such as polyurethane in a state in which the wire rope 10 is seated on the mold through the center of the bead 30 spaced at regular intervals It is manufactured by integrally molding the synthetic resin layer 20 having a cross section, and the beads 30 protrude from the synthetic resin layer 20 on the shank 32 and the outer surface of the shank embedded in the synthetic resin layer 20. It is composed of a polishing layer 34 in which the diamond abrasive grains are integrally incorporated. Prior arts related to such a diamond endless wire rope saw 60 include Patent Document 2, Patent Document 3, and the like.

Typically, such diamond endless wire rope saws have a diameter of at least 2 mm that allows beads to adhere to the wire rope by means of synthetic resin. That is, in the molding method by the synthetic resin, the beads could not be fixed to the wire rope having a diameter of 2 mm or less. By the way, when the diameter of the wire rope is large, the loss of the cutting object (raw material) is large and the cutting precision is inferior. In particular, when cutting an ingot of a silicon wafer, which is an expensive cutting object, not only the production cost increases but also a considerable time for cutting, and in addition, many silicon slurries are generated, which is disadvantageous for the environment. There is this.

Patent Document 1: Korean Patent Publication No. 2006-0118392

Patent Document 2: Korean Registered Patent No. 0371832

Patent Document 3: Korean Registered Patent No. 0669850

Accordingly, the present invention has been found that the above-described problems can be solved when brazing or soldering the wire rope and the beads using a metal in the manufacture of the diamond wire rope saw, and the present invention has been completed based on this.

Accordingly, an object of the present invention is to provide a diamond endless wire rope saw having excellent bead adhesive strength and excellent wire rope tensile strength.

Another object of the present invention is to provide a method for manufacturing the diamond endless wire rope saw.

Diamond wire rope saw according to the present invention for achieving the above object:

Endless wire ropes; A plurality of beads inserted into the wire ropes at equal intervals and having a diamond brazed on an outer surface of the shank; Consists of a synthetic resin coated between the beads and the beads, characterized in that the beads are brazed or soldered with the wire rope by a metal.

In the diamond wire rope saw according to the present invention, the material of the wire rope is steel alloy, SUS or tungsten alloy, its diameter is characterized in that 0.2 to 1.5mm.

In the diamond wire rope saw according to the invention, the metal is characterized in that the tin-based metal, lead-based metal, silver-based metal, copper-based metal or zinc-based metal.

In the diamond wire rope saw according to the present invention, the synthetic resin is diamond powder, silicon carbide (SiC) powder, green carboramtam (GC) powder, alumina (Al ₂ O ₃ ) powder, tungsten powder, tungsten carbide powder, or It characterized in that it further comprises a cemented carbide powder.

In the diamond wire rope saw according to the present invention, the surface of the war rope or the inner surface of the shank is characterized in that the copper plating, nickel plating or tin plating.

Method for producing the diamond wire rope saw for achieving another object of the present invention is:

In the manufacturing method of the diamond endless wire saw,

Providing diamond beads brazed with diamonds to the wire rope and shank outer surface; Inserting a plurality of said beads into said wire rope; Binding both ends of the wire rope to endlessize; Applying flux or metal paste at equal intervals to the wire rope and placing the beads at the application site; Soldering the wire rope on which the beads are placed at 600-900 ° C. or soldering at 200-450 ° C .; And coating the beads between the beads with a synthetic resin.

In the production method of the present invention, the wire rope is a steel alloy, SUS or tungsten alloy, its diameter is characterized in that 0.2 to 1.5mm.

In the production method of the present invention, the metal paste is characterized in that the tin-based metal paste, lead-based metal paste, silver-based metal paste, copper-based metal paste or zinc-based metal paste.

In the production method of the present invention, the synthetic resin is characterized in that the polyurethane resin or UV curable resin.

In the production method of the present invention, the synthetic resin is a diamond powder, silicon carbide (SiC) powder, green carboramtam (GC) powder, alumina (Al ₂ O ₃ ) powder, tungsten powder, tungsten carbide powder, or cemented carbide powder It is characterized by containing 1-15 weight% further with respect to the whole resin.

In the manufacturing method of the present invention, when the flux is applied, brazing or soldering while supplying tin-based wire, lead-based wire, silver-based wire, copper-based wire or zinc-based wire in the brazing or soldering step between the bead and the wire rope. It features.

As such, the endless wire rope saw according to the present invention is not only excellent in durability such as bond strength of the beads and tensile strength of the rope, but also a relatively thin cutting width, so that the loss of raw materials is small and precision cutting is possible. In addition, the endless wire rope saw according to the present invention is not only capable of multi-cutting but also very fast cutting speed, it is very easy to remove, mount and replace the wire rope saw. In addition, the endless wire rope saw according to the present invention can rotate and rotate so that the diamond can work as much as the circumference has a long life effect of the wire rope saw.

Hereinafter, with reference to the accompanying drawings of the present invention will be described in more detail.

2 is a cross-sectional view showing a diamond endless wire rope saw according to an embodiment of the present invention, Figure 3 is a cross-sectional view showing a diamond endless wire rope saw according to another embodiment of the present invention, Figure 4 is This is a process diagram schematically illustrating a process of manufacturing a diamond endless wire rope saw.

2, the diamond endless wire rope saw 600 according to the present invention is an endless wire rope 100; A plurality of bead 300 is inserted into the outer surface of the wire rope 100 at equal intervals, the bead 300 is a diamond brazed on the outer surface of the shank; And a synthetic resin 200 coated between the beads and the beads.

According to another embodiment of the present invention as shown in Figure 3, the endless wire rope 100; Beads 300 are inserted into the outer surface of the wire rope 100 at equal intervals, the diamond brazed on the outer surface of the shank; And a synthetic resin 200 coated between the beads and the beads, wherein the synthetic resin 200 further includes an abrasive powder 400.

In the present invention, the bead 300 is brazed or soldered to the wire rope by the metal 500. The synthetic resin is a polyurethane resin or UV curable resin.

In addition, the bead 300 is a cylindrical shank 320 brazed or soldered to the wire rope by the metal 500 and the polishing layer 340 containing the distribution of the brazed diamond protruding from the synthetic resin 200 on the outer surface of the shank It consists of. In addition, the surface of the wire rope 100 and the inner surface of the shank 320 may be plated to increase the bonding force.

Accordingly, the diamond endless wire rope saw 600 according to the present invention has a structure in which the wire rope 100, the synthetic resin 200, the beads 300, and the metal 500 are organically combined. In addition, the diamond endless wire rope saw 600 according to the present invention may optionally further comprise abrasive powder 400.

In the present invention, the wire rope 100 may be a steel alloy (for example, piano wire), stainless steel (hereinafter referred to as "SUS"), or tungsten alloy. In all cases where the cross section of the wire rope is 1 × 7 (with 6 sheaths twisted on one central core wire), 3 × 9, 7 × 7, or 7 × 19, the diameter of the wire rope is especially Although not limited, Preferably it is less than 1.5 mm, More preferably, it is 0.2-1.5 mm, More preferably, it is 0.5-1.1 mm. As such, since the diameter of the wire rope is very thin, the material of the wire rope is preferably a steel alloy (piano wire) or a tungsten alloy in terms of strength. Table 1 shows the strength of the wire rope having a cross section of 1 × 7 according to each material.

Steel alloy (piano wire) SUS Tungsten alloy thickness 1.0 mm 1.05 mm 1.0 mm Breaking force 1.17 kN 1.04kN 1.14 kN

In the present invention, the brazing or soldering is a tin metal, lead-based metal, silver-based metal, copper-based metal or zinc-based metal is applied to the wire rope in the form of a paste or flux applied, and then the subsequent process is brazing, 600 ~ The wire rope and the beads are brazed at about 900 ° C, preferably at about 650 to 750 ° C. Preferred metals for brazing are silver-based metals, specifically silver lead.

On the other hand, when the subsequent process is soldering, the wire rope and the beads are soldered at about 200 to 450 ° C, preferably at about 250 ° C. Preferred metals for the soldering are tin-based metals, for example, Sn-Ag-Cu, Sn-Ag or Sn-Cu.

In addition, when brazing or soldering by applying the flux, it is brazing or soldering while supplying tin wire, lead wire, silver wire, copper wire or zinc wire between the beads and the wire rope.

The synthetic resin is an abrasive grain such as diamond powder, silicon carbide (SiC) powder, green carboramtam (GC) powder, alumina (Al ₂ O ₃ ) powder, tungsten powder, tungsten carbide powder, or cemented carbide powder. It may further comprise 1 to 15% by weight. The abrasive grains may be included in a synthetic resin to increase cutting force and wear resistance of the wire rope. That is, there is an effect of having the cutting force itself while minimizing the loss of synthetic resin during cutting by the added abrasive powder. If the added amount of the powder is less than 1% by weight, the effect of addition is insignificant, and if it exceeds 15% by weight, the flexibility of the wire rope is decreased, and the adhesion between the wire rope and the resin, and the resin and the abrasive powder tends to be inferior. In addition, the size of the powder is not particularly limited, but 100 to 600 mesh is preferable, and if it is less than 100 mesh, the particles tend to be too large to fall out of the resin layer, and if it exceeds 600 mesh, it is large for improving the wear resistance of the wire rope. It doesn't help

According to the present invention, the wire rope surface and the shank inner surface of the bead may be plated with metal to increase the brazing or soldering efficiency. The plating at this time is preferably copper plating, nickel plating or tin plating.

Meanwhile, referring to FIG. 2 to FIG. 4, the manufacturing process of the present invention will be described in detail. First, the wire rope 100 and the shank 320 are washed and degreased, and then, the diamond is formed on the outer surface of the shank 320. The powder 300 is brazed in a conventional manner to prepare the beads 300. The metal powder may be nickel (Ni) alloy or silver (Ag) lead. In particular, the nickel is the most used component is excellent in tensile strength, very good bonding force with diamond.

Then, optionally, the surface of the wire rope 100 and the inner surface of the shank 320 may be plated. The plating at this time is preferably copper plating, nickel plating or tin plating, and may be plated by a method such as electrolyte plating or electroless plating.

According to the present invention, the bead 300 is inserted into the wire rope 100, and then loosened both ends of the wire rope 100 to bind in both directions to endless the wire rope 100. For example, in the case of a wire rope having a cross section of 7 × 7 or 7 × 19, out of the six covering wires surrounding one core at one end, three strands are loosened, and the three strands interposed therebetween After shortening, at the other end of the three strands corresponding to the short three strands loosen long, the three strands corresponding to the long three strands are made short and twisted in both directions to bind each other, the at least three sites (core The wire rope can be endlessized by placing and fixing a bead at one site where it meets, and two sites where the three long sheaths meet the short sheath.

The endless wire rope 100 is coated with a flux or a metal paste for brazing or soldering at the site where the bead 300 is to be placed, and then places the bead 300 at a site where the flux or paste is applied. Fix it.

The wire rope 100 to which the beads 300 are fixed is placed in a dedicated brazing or soldering apparatus capable of heating only beads maintained at 600 to 900 ° C. or 200 to 450 ° C., thereby allowing the beads 300 and wire rope 100 to be heated. ) Is brazed or soldered to the metal 500. In particular, in the case of applying a flux other than the metal paste, when the metal wire is supplied between the bead and the wire rope in a dedicated brazing or soldering apparatus, the wire may be melted and the bead and the wire rope may be brazed or soldered.

As such, the metal 500 is provided in paste or wire form and brazed at 600 to 900 ° C. or soldered at 200 to 450 ° C. in the brazing or soldering step. In brazing, if the temperature is less than 600 ° C., the brazing tends to be too late or incompletely brazed, and if it exceeds 900 ° C., the beads including wire rope or shank deteriorate. In soldering, when the temperature is less than 200 ° C., the soldering tends to be too late or incompletely soldered, and when the temperature exceeds 450 ° C., the bonding strength may decrease.

When the bead 300 is brazed or soldered to the wire rope 100 by the metal 500, the beads 300 and the bead 300 are made of synthetic resin such as polyurethane or UV curable resin by using a coating equipment. Coating to form a layer of synthetic resin (200) to produce a diamond endless wire rope saw of the present invention.

On the other hand, the synthetic resin layer 200 is formed between the bead 300 and the bead 300 serves to support the bead 300, while ensuring the flexibility of the wire rope saw to directly wear the wire rope 100 It is used for the purpose of preventing and optionally abrasive grains such as diamond powder, silicon carbide (SiC) powder, green carboramtam (GC) powder, alumina (Al ₂ O ₃ ) powder, tungsten powder, tungsten carbide powder, or cemented carbide powder. It is possible to further increase the cutting force of the wire rope by further comprising 1 to 15% by weight of the powder as a whole of the resin, and also improve the wear resistance of the synthetic resin.

In the present invention, the UV curable resin has a vinyl (Vinyl) group, that is, an unsaturated group component such as C = C in the resin molecular structure, when the light (ultraviolet) receives the photoinitiator is activated and crosslinked through the initiation reaction of free radicals It refers to a resin that hardens by bonding and polymerizing (Gel).

Hereinafter, the present invention will be described in more detail with reference to the following examples, but the scope of the present invention is not limited to the following examples.

Example 1

Beads were prepared by washing wire rope and shank of steel alloy (piano wire) material having a diameter of 1.0 mm and having a cross section of 7 × 7, and then brazing diamond with nickel (Ni) on the outer surface of the shank. A plurality of the beads were inserted into the wire rope, and both ends of the wire rope were bound to endlessly. The beads were placed on the site where the paste was applied, applying silver lead paste at equal intervals to the wire rope. The wire rope on which the beads were placed was placed in a brazing apparatus that only heated the beads and brazed at about 700 ° C. Then, the bead and the beads were coated with polyurethane using a coating equipment to prepare a diamond endless wire rope saw of the present invention.

Example 2

Beads were prepared by washing wire rope and shank of steel alloy (piano wire) material having a diameter of 1.0 mm and having a cross section of 7 × 7, and then brazing diamond with nickel (Ni) on the outer surface of the shank. A plurality of the beads were inserted into the wire rope, and both ends of the wire rope were bound to endlessly. The beads were placed on the flux-coated area, while flux was applied to the wire rope at equal intervals. The wire rope on which the beads were placed was placed in a brazing device that only heated the beads and brazed at about 700 ° C. while feeding the silver lead wire. Then, the bead and the beads were coated with polyurethane using a coating equipment to prepare a diamond endless wire rope saw of the present invention.

Example 3

Beads were prepared by washing wire rope and shank of steel alloy (piano wire) material having a diameter of 1.0 mm and having a cross section of 7 × 7, and then brazing diamond with nickel (Ni) on the outer surface of the shank. Then, the surface of the wire rope and the shank inner surface of the bead were electroless plated with copper. A plurality of the beads were inserted into the wire rope, and both ends of the wire rope were bound to endlessly. The beads were placed in the site where the paste was applied, while applying tin-based (Sn (96.5 wt.%)-Ag (3 wt.%)-Cu (0.5 wt.%) Paste to the wire rope at equal intervals. The wire rope on which the beads were placed was placed in a soldering apparatus that only heated the beads and soldered at about 250 ° C. Then, the bead and the beads were coated with polyurethane using a coating equipment to prepare a diamond endless wire rope saw of the present invention.

Example 4

Beads were prepared by washing wire rope and shank of steel alloy (piano wire) material having a diameter of 1.0 mm and having a cross section of 7 × 7, and then brazing diamond with nickel (Ni) on the outer surface of the shank. A plurality of the beads were inserted into the wire rope, and both ends of the wire rope were bound to endlessly. The beads were placed on the site where the paste was applied, applying silver lead paste at equal intervals to the wire rope. The wire rope on which the beads were placed was placed in a brazing apparatus that only heated the beads and brazed at about 700 ° C. Then, the diamond endless wire rope saw of the present invention was manufactured by coating the beads between the beads with a polyurethane containing 5% by weight of diamond powder having a particle size of about 325 mesh using a coating equipment.

Thus, the bond strength and tensile strength of the wire rope saws according to Examples 1 to 4 and after cutting (after use) of the Poly-Si ingot under the following conditions were measured and described in Table 2 below. In addition, the cutting speed and life of the endless wire rope saw according to the present invention was measured and described in Table 3.

-Cutting conditions

1.Material: Poly-Si ingot 5th generation block 830 × 830 × 250㎜

2. Cutting equipment: Multi type dedicated M / C

3. Cutting size: 25 bars / 1 ingot of 156 × 156 × 250㎜

4. Cutting method: X-axis 6 lines, Y-axis 6 lines simultaneous multi-cutting

division Example 1 Example 2 Example 3 Example 4 Bead Bonding Strength Before use 90 kgf 90 kgf 70 kgf 90 kgf after use 90 kgf 90 kgf 60 kgf 90 kgf Endless wire rope
The tensile strength Before use 100 kgf 100 kgf 100 kgf 100 kgf after use 60 kgf 60 kgf 60 kgf 80 kgf

division Example 1 Example 2 Example 3 Example 4 Endless wire rope
Cutting speed 2.5hrs / 1 ingot 2.5hrs / 1 ingot 2.5hrs / 1 ingot 2.5hrs / 1 ingot 5th generation block
(830 × 830 × 250mm) 20 cuts 20 cuts 18 cuts 24 cuts Bar
(156 × 156 × 250mm) 500 cuts 500 cuts 450 cuts 600 cuts Life of average wire rope saw 41.6 Bar 41.6 Bar 37.5 Bars 50 Bars

On the other hand, using a wire rope saw according to Examples 1 to 4 was measured in the cut state of the silicon bar (Bar) shown in Table 4 below.

wire Square ¹⁾ Croper ²⁾ Drive rpm 5100 rpm Roughness (Rmax) 40㎛ ↓ Roughness (Rmax) 40㎛ ↓ Length 4605 mm Squareness ± 0.15 ° Squareness ± 0.15 ° Mesh size 60/80 # flatness ± 0.15 mm flatness ± 0.15 mm Cutting fluid water - - - -

1) is the process of blocking ingots into squares, and 2) is the process of cutting the top and ends of the square blocks.

As can be seen from Tables 2 to 4, the endless wire rope saw according to the present invention has excellent durability, such as bonding strength and tensile strength, both before and after use, and can be cut very thinly, resulting in loss of raw materials during cutting. In addition, the cutting conditions such as roughness, squareness, and flatness of the cut bar are excellent, so that precise cutting is possible. In addition, the endless wire rope saw according to the present invention is not only multi-cutting is possible, the cutting speed is very efficient, the life of the wire rope saw is long, there is an effect that the removal and installation is very easy.

1 is a cross-sectional view showing a diamond wire saw according to the prior art,

2 is a cross-sectional view showing an example of a diamond wire rope saw according to the present invention,

3 is a cross-sectional view showing another example of a diamond wire rope saw according to the present invention,

4 is a process diagram schematically showing a process of manufacturing a diamond wire rope saw according to the present invention.

-Explanation of symbols for the main parts of the drawing-

10, 100: wire rope 20, 200: synthetic resin

30, 300: Bead 32, 320: Shank

34, 340: abrasive layer 400: abrasive grains

500: metal 60, 600: diamond wire rope saw

Claims (11)

Endless wire ropes; A plurality of beads inserted into the wire ropes at equal intervals and having a diamond brazed on an outer surface of the shank; Diamond bead end wire rope saw, characterized in that made of a synthetic resin coated between the beads and the bead is brazed or soldered (soldering) with the wire rope by a metal. The method according to claim 1, The material of the wire rope is a steel alloy, SUS or tungsten alloy, the diameter of the diamond endless wire rope saw, characterized in that 0.2 ~ 1.5mm. The method according to claim 1, The metal is a diamond endless wire rope saw, characterized in that the tin-based metal, lead-based metal, silver-based metal, copper-based metal or zinc-based metal. The method according to claim 1, The synthetic resin further comprises a diamond powder, silicon carbide (SiC) powder, green carboramtam (GC) powder, alumina (Al ₂ O ₃ ) powder, tungsten powder, tungsten carbide powder, or ultrafine powder Diamond endless wire rope saw. The method according to claim 1, A diamond endless wire rope saw, wherein the surface of the war rope or the inner surface of the shank is copper plated, nickel plated or tin plated. In the manufacturing method of the diamond endless wire saw, Providing diamond beads brazed with diamonds to the wire rope and shank outer surface; Inserting a plurality of said beads into said wire rope; Binding both ends of the wire rope to endlessize; Applying flux or metal paste at equal intervals to the wire rope and placing the beads at the application site; Soldering the wire rope on which the beads are placed at 600-900 ° C. or soldering at 200-450 ° C .; And Coating the beads between the beads with a synthetic resin; Method of producing a diamond endless wire rope saw comprising a. The method according to claim 6, The wire rope is a steel alloy, SUS or tungsten alloy, the diameter of the diamond endless wire rope manufacturing method, characterized in that the 1.5mm. The method according to claim 6, And said metal paste is a tin-based metal paste, a lead-based metal paste, a silver-based metal paste, a copper-based metal paste or a zinc-based metal paste. The method according to claim 6, The synthetic resin is a method of producing a diamond endless wire rope saw, characterized in that the polyurethane resin or UV curable resin. The method according to claim 6, The synthetic resin is a diamond powder, silicon carbide (SiC) powder, green carboramtam (GC) powder, alumina (Al ₂ O ₃ ) powder, tungsten powder, tungsten carbide powder, or cemented carbide powder 1 to 15% by weight of the whole resin Method for producing a diamond endless wire rope saw, characterized in that it further comprises%. The method according to claim 6, When the flux is applied, the diamond endless wire rope saw, characterized in that brazing or soldering while supplying tin-based wire, lead-based wire, silver-based wire, copper-based wire or zinc-based wire between the bead and the wire rope in the brazing or soldering step. Manufacturing method.

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