TW442370B - Diamond wire saw cutting machine - Google Patents

Abstract

This invention is to develop machine tool utilizing a diamond wire saw to cut a non-conductive material. The cutting method is similar to that of the EDM, and can be used to cut the hard and brittle materials, such as ceramics, composite materials, silicon and so on, which can not be machined to the required shape by conventional machining method. This machine tool is a machine utilizing a controller mainly the personal computer to proceed numerical control. The machine uses a diamond wire saw moving in Z-axis or a certain direction to achieve the cutting function. Instead of conventional threading and reeling, winding type of the diamond wire saw is used for easy assembling and disassembling. When used for cutting a specified shape, the shape can be defined numerically, and the X- and Y-axis displacement of the workpiece is controlled by numerical control, so as to control the cutting accuracy within the required range. This cutting machine comprises a guiding wheel set installed before and after the workpiece, which rotates along the extension direction of the diamond wire saw by means of the rotating disk and the rotating beam to give the supporting reaction force no matter what the cutting angle is. Besides, a tension control mechanism is provided under the passive roller to maintain a constant tension. High resolution analysis of optical video camera is also used to measure the degree of wire bending, so as to obtain the cutting force and the reaction force of the workpiece by cuculation, and then the rotational speed of the motor is adjusted to change the wire pulling speed of the diamond wire saw and the workpiece feeding speed, so as to achieve the object of cutting accurately.

Description

442370 V. Description of the invention (1) μ i :: ί: A diamond wire saw can not be used to process materials, ceramics, etc. This machine can cut wafers with high hardness, brittleness, etc ... To make up for the traditional processing methods 4 η # and 2 to solve the various problems of emerging materials processing and cutting. Need to process the ingot and cut it into wafers. When the size of the wafer is larger, such as twelve, tons es ay _ only 'ten / inch ... net, the problem of ingot cutting' is difficult to use today's processing technology Such as diamonds and other emerging ^ ^ ^ ,, M ^ / p ^ _ Tao is a material processing, but also faces problems: because of ceramics! Material has a variety of characteristics and uses, such as heat resistance, corrosion resistance, high hardness, fashion Strong, good thermal conductivity and electrical insulation and its magnetic properties can be used as' electricity 'for special functions such as sensing, control, etc. Yuan Taoshen ^ Electric Tao Yao Materials' medical ceramics materials. Because the ceramic material branch can be used for general materials (to the purpose, but its brittleness is relatively old, n "gang #) can not go against the traditional tradition-Erkou =:, ... The ancient quality of the parts is not the same as the processing quality and accuracy of the parts, and it is difficult to cut the ultra-precision parts with the traditional processing methods. The cost is as follows: r requires different cutting methods. To cope with. 的 零零 #, we chose the diamond wire ore field knife. 丨 Knife Eight, mainly to attach diamond particles to the piano wire through various brazing methods. Make the diamond sticky, electroplated, or steeper than the diamond knife. Better cutting performance. In addition, it is more solvable

442370 V. Description of the invention (2) The crystal structure of the highly brittle material will affect the characteristics of the material when the friction temperature rises; therefore, == drill: II: ΐ cutting t will have ore-like shape, or surface at f Γ & Trauma occurred. In addition, when cutting fragile crystals, the sharp vibration of the fixture can be avoided to break the workpiece into fragments. Due to the diamond thread's transmutation, it will suppress the vibration when it contacts the workpiece. It is more suitable for cutting than traditional cutting tools such as round abrasives. Brittle material. Furthermore, the area of the spar line and the workpiece "is very small, and new diamond particles are constantly in contact with the workpiece during cutting.] When cutting any material, the frictional heat generated is less than that of traditional tools, and the surface is adhered after cutting. The wear degree of diamond particles is very small. In the market, there are very few machines that use diamond wire saws for cutting. The patent of US4,016,856 talks about a kind of diamond wire mine cutting machine. In April 977, the patent validity period was lost. The two are not computer-controlled and use threading instead of winding. Therefore, the 2-cut speed and accuracy are poor, and only simple shapes can be cut, and precision processing cannot be achieved. Purpose 'In this patent, its cutting accuracy is not high, only reaching ± 25,4 Am. In addition, the US patent No. 55644〇9 also uses alloy wires to cut discs. Since the 5xuan patent uses alloy wires and Abrasive grains are used for cutting instead of using diamond wire ore. Therefore, it is different from the application purpose of this patent invention. For this reason, the present invention specifically improves the disadvantages listed above. 'Using pc_BASED control' makes the cutting of special materials Precision, to achieve the industry needs. '' Shown on the object of the present invention is to design a winding type mechanism 'so that the diamond wire saw easy to install, saving installation time.

/ 14237 0 V. Description of the invention (3) The second purpose of the present invention is to design the diamond wire saw into a ring type, which can save a lot of manufacturing costs. The third object of the present invention is to design a force adjustment mechanism so that when the machine cuts, the tension can be adjusted by itself to prevent the diamond thread from breaking. The fourth object of the present invention is to design a guide wheel mechanism for supporting a diamond wire saw, so that when the machine cuts in any direction, the thrust force of the workpiece feed is always opposite to the direction of the counterforce given by the wire mine. The fifth object of the present invention is to design an offset sensor, which can measure the offset of the diamond line when the machine is cutting; when the offset is too large, feedback control and correction can be performed to achieve the purpose of precision machining. In order to make the examiner of the Bureau more clear about the effectiveness of the patent of the present invention, the detailed description is as follows: Figure: The vertical mechanism of the diamond wire saw cutting machine (Figure 1) Figure 1 The top view of the relative position of the diamond wire saw and the guide wheel set— — Fig. 4 Side view of the guide wheel guide wheel set 4 Fig. 4 Top view of the guide wheel guide wheel set and guide wheel set 5 Fig. 5 Enlarged view of the optical camera (optical measuring lens) 6 Fig. 7 Force diagram of the diamond wire saw Figure Diamond wire saw deformation analysis chart Figure 8 Diamond wire saw cutting machine horizontal mechanism Drawing number: 1 diamond wire saw 2 drive roller

442370 、 Explanation of invention (4) 3 A passive roller 5 C passive roller 7 load line 9 load 1 1 offset (tension) 1 3 optical camera 1 5 upper guide wheel stage 1 7 clamp 1 9 A belt 2 1 CNC bed control 2 3 β pulley 2 5 XY NC bed 2 7 Nozzle 2 9 Optical lens 3 1 Data cable outlet 3 3B Optical camera 3 5 Body 3 7 Β Guide wheel 4 Β Passive roller 6 Rotary rod 8 Load roller] _ 0 Work feel Detector 1 2 rotating beam 1 4 table 1 6 lower guide wheel set 1 8 drive motor 2 0 Α belt pulley 22 rotating disk motor 2 4 rotating disk 2 6 image capture + 2 8 bracket 3 0 light source wheel into α 3 2 Α optical camera 3 4PC 3 6 A guide wheel 3 8B belt In order to achieve the purpose of precise processing as described in the first picture, as shown in the first picture, the Ø Z line ore / clothing around the drive roller 2 'before passing through the A passive roller 3, β passive: 4 and C break the roller 5 to complete a loop 'drive roller 2, and three, Ϊ 4 2 5 are installed in the body 3 5 and in a cantilever-like manner, so first. Put the completed diamond wire saw ring directly on the 'no more mining

V. Description of the invention (5) The conventional winding and winding method 'because diamond wire saws' are not easy to make and the price is high. The winding method must use a longer diamond wire saw segment, so it is directly set in a ring manner. Can greatly save costs "c Passive roller 5 is installed on the rotating rod 6 'and a load line 7 is pulled out by the rotating rod 6 through the load roller 8 and a weighted load Θ of an appropriate weight is suspended to make the diamond wire saw ring Before the uncut workpiece 10, 'bear a certain tension; and when the diamond wire saw ring is put on, the rotating fine adjustment of the passive roller can easily put the diamond wire saw ring on a large number of knots,' Time required. According to the Japanese literature, 7 ^ Grain Processing Society Journal Vo 1 · 43 No. 1 1999 JAN. 40-41) ,,, paper, 'Delete the diameter of 0 · 2 produced by the lightning + welding butt joint method, and The stone wire staggered ring with Qin steel wire as the base material can withstand a pulling force of about 2 kg, so the i drill with a counterweight load g can be based on this. The design of fixing the tension of the diamond wire saw 1 is based on the use of a negative load line 7 on the rotating rod 6 where the wheel 5 is located, and a suitable load 9 is rolled through the load 1 to make the diamond wire saw 1Withstand a certain tension, ^ / When the tension increases due to hanging cutting, the bending of the wire can make the rotating rod 6 clockwise ^ 仃 cut and swing, 玎 avoid the diamond wire saw that is closed and joined. Breaking '$ to the automatic tension adjustment function, while the cutting time and continuous cutting damage are more accurate: long lasting' surface is beautiful. If you change the diamond line, you can use the following description. Chip volume k Ma Zhi (1)

V = KvM

442 37 〇 5. Description of the invention (6) Among them, K: chip volume (CC) M · diamond abrasive grain weight (gram) center: volume constant, related to the nature and hardness of the cutting material. For example, cutting granite can cut 1 0, 0 0 0 cc; while cutting softer marble can cut a volume of 1 0 0, 0 0 0 CC. The weight of diamond abrasive grains can be obtained from the following formula: M = nDLpd ί 2 (2) where Z): diamond wire diameter (cm) i: diamond wire loop length (cm) diamond density (g / cm 3) J : Diameter of diamond abrasive grains (cm), which is usually equal to the chip volume and can be equal to the following formula V ^ AD (3) where / is the area of the workpiece after diamond wire cutting. According to the formulas (1)-(3), the relationship between the unit length of the diamond wire and the cutting area can be expressed as: A! L two KK ', πνάII 钻石 From the formula (4) and the length of the diamond wire ring, a diamond can be obtained > Wire saw

Page II 44237 〇 5. The life of the invention (7). The diamond wire saw offset sensor 11 is installed on the rotating beam 12 because the offset sensor 11 is composed of an optical camera 1 3, so that it can be known that the diamond wire record 1 is cutting the diamond wire The offset of the saw 1 further controls the diamond wire saw 1 to achieve a certain degree of support. And the workpiece 10 is placed on the worktable 14 between the upper guide wheel set 15 and the lower guide wheel set 16, and the work piece 10 is fixed on the worktable 14 by using the fixture 17. The diamond wire saw 1 is fixed in a certain position and can move rapidly in a single direction. The rotation of the drive motor 18 drives the A belt 19 to rotate the B pulley 20 ', and then drives the roller 2 to rotate the diamond wire saw 1 so that the diamond wire saw 1 follows the fixed direction and The path moves. Together with the numerical control of the CNC bed controller 21, the workpiece 10 can be cut and processed into complex shapes. Referring to the first and sixth figures, under the fixed tension of the diamond wire heterocyclic ring, in order to make the diamond wire saw 1 receive the smallest amount of deformation and can withstand external forces in different directions when it is subjected to external forces, the upper and lower ends of the workpiece are individually Install the upper guide wheel set 15 and the lower guide wheel set 16 to minimize the deformation of the diamond wire saw 1. With the fine characteristics of the wire 1, the workpiece 10 can be cut more accurately and the diamond wire saw 1 can be forced. In the case of external force, the amount of deformation can still look like a straight line. When cutting the workpiece 10, the external force received will be complicated due to the cutting shape, and the opposite force will be generated in different directions. Therefore, the front disk B pulley 23 is rotated by the rotary disk motor 22, and the rotary disk is driven by the transmission of the B belt 38. 24 turns' The rotating disk 24 will rotate with the rotating beam 12 below, and the upper guide wheel set 15 and the lower guide wheel set 16 are installed on the rotating beam 12, so the diamond wire saw 1 is subjected to different directions in various situations. In the reaction force, it can still maintain a straight state. Cooperate with the offset sensor again to determine whether the diamond ore 1 is cutting

Page 12 442370 V. Description of the invention (8) -------- the situation of the offset 'and by adjusting the rotation speed of the drive motor 18 to change the cutting speed of the diamond wire saw 1 and adjust the X_Y bed 25 'Feed speed' can make cutting more accurate and achieve the required cutting accuracy. In addition, the combination of the rotating disk ^ red rotating beam 12, the upper guide wheel set 15 and the lower guide wheel button 16 has the purpose of rotating around the diamond wire saw 1. The groove of the guide wheel is used to achieve self-alignment: avoiding the diamond wire Mine shifts and twists. In addition, the design of the guide wheel set can also be designed as shown in the third figure, using: a guide wheel, an angle of 90 degrees and staggered up and down, ffl U) e is placed in the X direction of the force to support The distance between points will continue to change, but the workpiece will still be used as the midpoint; if it is set as shown in (b), the distance between the support points will not change, but the midpoint will continue to change; its top view is as shown in the fourth figure (A) The 'diamond line 1' is limited to the center of the guide wheel by four guide wheels, and will not be severely deflected due to cutting forces in other directions. Depending on the actual situation, the number of guide wheels can be reduced from four. Into three, with an angle of 20 degrees, as shown in the fourth figure (b); the use of a four-wheel or three-wheel guide wheel set, the biggest advantage is that there is no need to design the rotating disk 24 and rotating beam 12 Because the guide wheel encloses the diamond wire in the center at any time, there is no need to change the support position of the guide wheel set with the cutting direction. With reference to the first and second figures' in the upper guide wheel set 15 and the lower guide wheel set 16 ', in order to effectively support and resist external forces, it is mounted on the rotating beam 12' the rotating disk 24 is made of diamonds The extension direction of the wire saw 1 is the rotation center, which can rotate the rotating beam 12 according to the shape of the workpiece to be processed, and the entire upper guide wheel set 15 and the lower guide wheel set 16 can be changed to support the position of the supporting angle. Designs staggered up and down at right angles, that is, each guide wheel set

Page 13 Λ4237 〇 5. Description of the invention (9) Both the A guide wheel 36 and the B guide wheel 37 are included. Therefore, as long as the rotary disk 24 has a rotation angle range of about 270 degrees, it can cover a 360-degree working range. "The garden will not cause the situation where the guide wheel cannot support the external force vertically at certain angles; for this reason, the height of the worktable is supported by a single-sided and inboard bracket 2 8", although this structure is being designed There will be moments generated, but because it is mainly engaged in precision processing, the processed objects are mostly light, thin and short. 'As long as the rigidity, strength and size of the bracket 28 are selected properly, this problem will not cause much trouble. When the diamond wire saw 1 receives an appropriate reaction force, the wire saw is in a straight state, which makes the cutting more precise. In order to effectively control the accuracy when cutting the workpiece, and to allow the diamond wire ore 1 to control a certain range of deformation when moving in a single direction, the upper guide wheel set 15 and the table 14 An offset sensor Π is installed between the windows to find out how much the line is offset. Using the principle of computer vision, as shown in the fifth figure, it is an optical camera. The light source access port 30 can be connected to a fiber-optic halogen lamp source. , The coaxial epi-illumination method is used, and the wire diameter of the wire saw is enlarged by 80 to 120 times by the optical lens 29 to increase the resolution of the offset judgment. Then the data is transmitted to the image capture card 26 for reading through the data output line 31 and sent to pc34 for processing. When the deformation of the diamond line mine 1 is too large, it means that the feed rate during cutting is too fast or the wire drawing speed Too fast 'uses the judgment of the offset sensor 2 and converts it into a digital signal and sends it to PC34. PC34 controls the X-axis displacement, γ-axis displacement, rotary disk motor angle, and drive motor speed through a motion control card, which can reduce The feed rate of the workpiece reaches the required accuracy; in addition, a nozzle 27 can be added if necessary to avoid the cutting chips from affecting the detection result of the offset sensor.

Page U Λ4237 〇 V. Description of the Invention (-) --- Using the CNC bed controller 21 to control the bed movement, in the vertical position, we can not only cut the work in a single direction, but also process complex three-dimensional shapes. . Some predetermined shapes can be cut by using the digital control of C N C. Since the shapes can be quantified ', the required shapes can be efficiently processed by using the movement of the X and γ axes and the rotation of the rotary disk 24. Furthermore, in cooperation with the upper and lower guide wheel sets 15 and 16, and the offset sensor 11, the diamond wire saw i can withstand loads and forces in various directions. In order to prevent the dust generated by the workpiece 10 from being cut to affect the result of the optical camera 13, adding a nozzle 27 at the same height and vertical position can solve the problem of dust accumulation on the lens of the optical camera. The offset sensor is installed on the rotating beam 2 like the guide wheel set, and is sandwiched between the two guide wheel sets, as shown in the seventh figure of the optical camera A and optical camera 32 and 3 devices. Refer to the seventh picture 'In terms of the force of diamond wire mine 1, the tension and timing of the diamond wire saw ## The force of T2 and T3 is fixed. When the diamond wire mine i is subjected to the shear force, it comes from Ft and Fn', which will affect θ2. And θ3, and Ft ^ Fn ^ is determined by the line speed and workpiece feed rate Vn, so we σ

The light and shadow machine Π 'is cutting the workpiece i. The relationship between the two sides of each device is as follows: 于 呢 J T2 cos θ2-73 cos 〇ι-Ft r2sini? 2 + r3sin = Fn

Λ42 3 7 Ο

V. Description of the invention (π) Θ2 and Θ3 can be obtained by the optical camera 13 for the size and image length of the diamond wire saw. The angle of the image is calculated using triangular geometry. When θ 2 and ㊀3 exceed the set value, it affects the accuracy requirements. At this time, the workpiece feed Vn can be reduced to make Θ2 and Θ3 smaller. In actual use, in order to save costs, only one optical camera 13 can be used, as long as θ2 or θ3 is measured, and correction can be used as precision feedback. @ 声 也 ί1 The method of making θ 2 and ㊀ 3 has to change the wire drawing speed and workpiece feed: for moving roller L, draw 4 wires: ^ It is mainly constant speed to avoid driving the roller 2 to make diamond wire ore; Qu: / Consumption 'Only adjust the workpiece feed rate' to control the change of cutting direction 1 and again. Generally speaking, in the χ-y plane, if there is no cutting direction, ^ 仏 can use a larger value for the feed rate. If the direction is often changed, the catch rate of X to y is lower. For example, first cut the X direction, and then cut the y edge 'instead of the I eight. You need to reduce the feed rate to cut out the vertical τ ϋ remnant. Referring to the eighth figure, the above method can also be used with the principle and design of the hot m 4 vertical diamond wire saw tool. Π is not the same as the vertical force machine. Method, machining complex shapes of workpieces

Claims (1)

442370 申请, patent application scope 1. 'A diamond wire saw with a diamond wire ore cutting machine for numerically controlled cutting. The type of diamond wire saw is no longer made with a winding method that is easier to load and unload — under the passive roller J Zhang Ding 9 When used to cut some predetermined X-pieces with numerical control to control the accuracy within the required range — this cutting machine includes a guide wheel set 5. It can also be designed in the direction of the extension of the diamond wire mine It can be made by four guide wheels or when cutting at any angle-using the analysis of the optical camera, the cutting speed of the workpiece can be known and the diamond wire saw can be changed to achieve accurate cutting. One of the winding mechanism drives Ro-Ro ax on the body, the structure can be simplified by the rock wire ore sleeve of the rotating rod 2. The diamond wire ring 1 as described in the patent scope 1 is no longer used as before Diamond wire because of the cost savings of diamond wire saws 0 3. As stated in the patent claim 1, it uses the personal computer as the main function; its characteristics are: the previous threading and winding type, and the diamond wire ring is used The force control mechanism can maintain the tension—the shape can be numerically defined during the shape, and the x and y axis movement positions, so that the cutting 9 is installed at the upper and lower ends of the workpiece, and the rotation can be driven by the rotating disk in the center ^ 2 The guide wheel group composed of guide wheels also gives support reaction force; degree analysis' measures the degree of wire bending, cutting force and reaction force, and then adjusts the wire drawing speed and workpiece feed speed of the motor, wheels and passive rollers Both can be adjusted by the swing arm beam, which can easily install the ring ^ and save installation time. The diamond wire saw cutting machine requires a long threading or coiling type in its design. The production cost is quite high, so it can save a lot of diamond wire cutting machine. Page 18 44237 0 Sixth, _ please patent scope The tension adjustment mechanism is to pull a load line on the rotating rod, and by hanging an appropriate load, the diamond wire saw can bear a certain overloading roller ~ ~ wave force to cut When the tension is increased, the bending of the wire can make the rotating rod cut in accordance with §, which can prevent the closed joint diamond wire saw from being subjected to too much tensile force, and the oblique direction of the oblique direction can cause breakage, and the automatic tension adjustment function can be achieved. The cutting time and continuity can make the cutting more accurate and the cutting table = ^ Long-term 4 The diamond wire saw cutting machine as described in the scope of patent application 1, the square turntable of f is set with the diamond wire mine extension direction as the rotation center , Can drive the guide wheel set on the rotating beam 'so that the wire saw can provide reverse support force when cutting in any direction; the upper and lower guide wheel sets are designed to stagger up and down and perpendicular to each other, so the rotating disc is only A rotation angle range of about 270 degrees is required to support a 360-degree working range '. Therefore, the table is only supported by the inner single-sided bracket; the groove on the guide wheel set still has the function of self-centering , To avoid the diamond wire saw offset and twist. 5. As for the diamond wire saw cutting machine described in the patent application scope 1, another design method of the guide wheel set in the design is to use four guide wheel angles of 90 degrees or three guide wheel angles of 120 degrees to make up and down. The staggered way is set so that the diamond wire can be limited in the middle of the guide wheel, and it can effectively support the diamond wire regardless of the cutting force in that direction, and no misalignment will occur. 6. As described in the patent claim 1, the diamond wire ore cutting machine 'the offset sensor in its design' is a computer vision principle that connects an optical camera to a fiber-optic halogen lamp source and illuminates in a coaxial epi-emission method , And the optical lens enlarges the wire diameter of the wire saw to increase the resolution of the misalignment judgment; it is then transmitted through the data output line, read by the image capture card, and finally sent to the computer for processing; when the wire saw Page 442 370 Page 20