TW201829102A - A cutting wire and method of manufacture - Google Patents

Abstract

A method for producing a coated wire rope, the method comprising the steps of: guiding an element to a first wire coating device; applying a metal and metal coated grit to said element; guiding said element to a second wire coating device; and applying a metal coating over said metal and metal coated grit; where the element is a wire, twisting a plurality of elements to form a wire rope, or; where the element is a wire rope, twisting a plurality of wires to form said element.

Description

Cutting line and manufacturing method thereof

The present invention relates to an apparatus and method for producing a cutting line for industrial use.

Wires coated with superabrasive materials such as diamond or cubic boron nitride (CBN) are cut, sliced and/or hard and brittle materials (like ceramics, glass, minerals, tantalum and sapphire wafers, etc.) An important tool in the field. These grinding lines are useful cutting tools to reduce surface damage and loss of cuts.

However, when used in different applications, the strength of the strands on which the abrasive materials are placed as "substrates" may not be sufficient to cut different materials.

For example, the automotive industry, aerospace and precision metals industries also require high-precision sawing, but the materials involved are much stronger, making traditional wear-resistant coating lines unsuitable.

In a first aspect, the invention provides a method for producing a coated steel cord, the method comprising the steps of: directing an element to a first line coating device; applying a metal and metal coating gravel to the element Directing the component to a second wire coating device; and applying a metal coating on the metal and metal coating gravel; wherein the component is a wire, twisting a plurality of components to form a steel cable, or; Wherein the component is a steel cable, and a plurality of wires are twisted to form the component.

Thus, by providing a step of forming a cable, the operator can be provided with a wide variety of design options to select a cable suitable for cutting various materials.

The first figure shows a schematic diagram of a diamond wire process 5 in accordance with an embodiment of the present invention. The process is a reel-to-reel process starting from the first reel 10 and ending with the end reel 70.

In another embodiment, the first reel can be a multiple reel that supplies a plurality of lines through the coating process. The line 20 spanning from the first reel 10 operates under tension through a plurality of tensioning pulleys 25 that are tensioned by a tensioning unit 15.

As mentioned above, the first reel 10 may in fact be a plurality of reels that supply a plurality of strands in parallel through the process 5. In a particular embodiment, when the strands are within the tensioning unit 15, a further twisting unit 17 can twist the strands such that a cable 22 projects from the tensioning/twisting units 15, 17. For this reason, the following description is directed to the individual wire 20, but the same applies to the wire rope 22. It will thus be appreciated that the pre-coated twist unit can be combined with the tensioning unit or can be an individual device within the process.

The wire 20 passes through the surface coating chamber 30. In a specific embodiment, the surface coating chamber 30 is subjected to an electrolytic treatment whereby the nickel-plated diamond particles 35 are supplied to the surface coating chamber 30, and the surface is coated. An electrolyte is supplied in the dressing chamber 30 and the recovery chamber 40. Prior to the surface coating chamber 30, the line passes through a processing station to remove unwanted material from the surface of the wire.

A wire 20 that is magnetized to attract nickel-plated diamond particles passes through the electrolyte, and then the diamond particles adhere to the wire, thereby forming a thin nickel plating. The line is then passed through a wash and rinse configuration 45 to a nickel plating stage 50 whereby further electrolysis is performed to form a particular thickness of nickel plating on the line. The electrolyte is again supplied from the replenishing tank 55 and recovered. In a specific embodiment, the juxtaposed coated strands can be twisted 47 to form a cable before entering the nickel plating stage 50, such that upstream, the individual strands can be coated with sand prior to twisting of the coating line. Then, twisting and twisting the twisted wire to form a coated steel cord.

Then, a washing and rinsing tank 60 is passed through the diamond and nickel-plated wire or wire wound on the end reel 70 before being shipped to the end user.

By replacing the wire 20 with a cable 22, the resulting product is a coated cable that includes sufficient strength for many different applications. The coated product can be designed for a particular application by varying the number of strands within the cable.

A specific number of strands within the cable may be as few as two or as many as five, or even as many as 25 strands, to achieve the cable prior to the coating process.

In addition to strength enhancement, a steel cable can provide a different abrasive profile based on a generally cylindrical peripheral surface of a single strand that can have edge peaks and valleys corresponding to multiple strands. So this can have the advantage of supplying a concentration point to speed up the grinding process.

Further, as the single strand breaks, the cable will gradually break, thus having a longer life. This also reduces the waste of the cut profile, as the cutting pass break line may occur in a single wire application, thus not only causing the cut line to be scrapped, but may also result in the scrapping of the item undergoing the sawing process. Therefore, the gradually broken steel cable can avoid this waste compared with the catastrophic fracture of the single strand.

Further, by providing a cable, the ends of the cable can be woven together to provide an endless loop. If docking is possible, it is the only possibility for a single strand, however the accuracy of this joint eliminates the possibility of using an endless loop cutting belt.

It will be appreciated that the range of wire diameters applicable to the cable is quite wide and can be as small as 100 microns, as large as 2 mm, with intermediate dimensions of 250 and 500 microns. Depending on the diameter of the cable and the desired application, the abrasive coated diamond particles may be 10, 40, 100 or even 200 micron sized particles.

In a further embodiment, rather than coating a cable in a prior embodiment, the cable is not coated, a separate strand can be applied and then twisted together, thus producing a strand of wire coated with strands. The details of these specific embodiments will be discussed with reference to Figures 2A through 2C.

Referring to the first figure and the above specific embodiment, instead of the twisting unit 17, a twisting unit 65 positioned adjacent to the end reel 70 is used to combine the parallel strands into a steel cable before being wound onto the end reel. .

In a third embodiment, the coated strands can be wound onto the end spool 70 for later twisting, such that in this particular embodiment, the twisting units 17 and 65 are omitted in the first figure.

Second A shows a longitudinal view of a cable 75 having a peripheral abrasive surface 80.

This can be accomplished in at least two different ways, with the second B diagram showing a cable 85 having a separate strand 90 containing a coating 95. In the particular embodiment of Figure 2B, the individual strands are coated and then twisted into a cable 85 to achieve the desired cutting line. As noted, the twisting that occurs after the coating process may occur at the same location as the coating process illustrated in the first figure, having a twisting unit 65 adjacent the end reel. Alternatively, the cable 85 can be twisted from a plurality of end reels later as a secondary process.

In an alternate embodiment, the inner strand 92, defined as having no exposed peripheral surface that aids in the cutting process, may be uncoated, thus saving material costs. Thus, such uncoated strands can be introduced into the twisting device from different reels. Similarly, the inner strands can be different materials having high tensile strength compared to the coated strands, thus further increasing the strength of the cut line.

The second C diagram shows an alternative configuration whereby the cable 100 includes a plurality of strands 105 to which the coating 110 is applied.

Please refer to the first figure, which is a configuration in which the uncoated strands are twisted by a twisting unit 17, and thus the end twisting unit 65 is not required. In this configuration, the coating is applied to the uncoated steel cord and subsequently wrapped into a coated steel cord as compared to the specific embodiment of the second steel wire having the coated strands.

In order to maintain the generality of the invention, in the context of the present embodiment, the generic term of the elements may be substituted for strands or cables. Thus, where the invention may include a strand or a cable, the term "element" may be substituted to describe either.

5‧‧‧Diamond line process

10‧‧‧ first reel

15‧‧‧ Tensioning unit

17‧‧‧Twisting unit; twisting station

20‧‧‧ line

22‧‧‧Steel cable

25‧‧‧tension pulley

30‧‧‧Surface coating chamber

35‧‧‧ Nickel-plated diamond particles

40‧‧‧Recycling room

45‧‧‧Washing and rinsing configuration

47‧‧‧Twist

50‧‧‧ Nickel plating stage

55‧‧‧Replenishment box

60‧‧‧Washing and washing tank

65‧‧‧Twisting unit; twisting station

70‧‧‧end reel

75‧‧‧Steel cable

80‧‧‧ peripheral grinding surface

85‧‧‧Steel cable

90‧‧‧Separate stocks

92‧‧‧Internal stocks

95‧‧‧Coating

100‧‧‧Steel cable

105‧‧‧ strand stocks

110‧‧‧Coating

The invention will be further elucidated with reference to the accompanying drawings in which the invention may be configured. Other configurations of the invention are also possible, and thus the particularity of the drawings should not be construed as a substitute for the generality of the foregoing description of the invention.

The first figure is a schematic illustration of a diamond wire process and/or system in accordance with an embodiment of the present invention.

Figures 2A through 2C are diagrams of a plurality of cut lines in accordance with many embodiments of the present invention.

no

Claims (4)

A method for producing a coated steel cord, the method comprising the steps of: directing an element to a first line coating device; applying a metal and metal coating gravel to the element; directing the element to a second wire coating device; and applying a metal coating on the metal and metal coating gravel; wherein the component is a wire, twisting a plurality of components to form a steel cable, or; wherein the component is a steel cable, A plurality of wires are twisted to form the component. The method of claim 1, wherein the metal and metal coating step comprises the steps of: applying a magnetic field to the element; introducing a mixture of the electrolyte and the metal coating gravel into the first coating device; The element is passed through the first coating device comprising at least one anode electrode while an electrical connection is applied to the element and the anode electrode. The method of claim 1, wherein the twisting step occurs when the metal coating gravel is applied and directed between the second coating devices. The method of claim 1, wherein the twisting step occurs after the metal coating is applied over the metal coated gravel.