WO2017186111A1 - 金刚石锯片切割性能的测试方法 - Google Patents

金刚石锯片切割性能的测试方法 Download PDF

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Publication number
WO2017186111A1
WO2017186111A1 PCT/CN2017/081945 CN2017081945W WO2017186111A1 WO 2017186111 A1 WO2017186111 A1 WO 2017186111A1 CN 2017081945 W CN2017081945 W CN 2017081945W WO 2017186111 A1 WO2017186111 A1 WO 2017186111A1
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grinding
cutting
diamond
saw blade
drilling
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PCT/CN2017/081945
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English (en)
French (fr)
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尹丁
郭和惠
邹辉
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成都惠锋新材料科技股份有限公司
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Priority to US15/774,585 priority Critical patent/US10677700B2/en
Publication of WO2017186111A1 publication Critical patent/WO2017186111A1/zh

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/56—Investigating resistance to wear or abrasion
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/58—Investigating machinability by cutting tools; Investigating the cutting ability of tools

Definitions

  • the invention belongs to the technical field of diamond tool testing, and particularly relates to a test method for cutting performance of a diamond saw blade.
  • the national standard “GB/T11170 super-hard abrasive products diamond circular saw blade” is one of the technical standards that China's super-hard tool field is in line with international standards and has a certain level, but there is no “cutting” on the actual performance of diamond circular saw blades. This important characteristic of performance "qualifies or quantifies.
  • the cutting performance of diamond circular saw blade is the core performance index of diamond circular saw blade.
  • the cutting performance of saw blade is determined by the actual cutting of specific objects and the performance of speed, load, consumption, tail retention and edge effect. Cutting performance.
  • machine tools, objects, and thrusts are simply referred to as “three elements of cutting”; the three elements of "tools, objects, and thrusts” involved in cutting have a great influence on the conclusion of cutting test, so it is necessary to achieve the three elements as much as possible. Only meet the basic principle of "same condition test".
  • the "machine” can be realized by the unified speed.
  • the "object” is unified by detailed agreement.
  • the difficulty lies in the control of the "passing thrust”.
  • the saw manufacturers are constantly exploring fair, objective and scientific.
  • Cutting test methods such as the manual propulsion cutting method, constant force cutting (weight hanging knives), limited power (current) cutting and fixed value cutting test, are not satisfactory.
  • Constant force cutting (weight hanging knives), power limiting (current) cutting and fixed value cutting cutting test methods are all “rigid” constant force testing methods, although the “rigid” constant force cutting method can solve the manual propulsion cutting There is a randomness problem in the method, but this "rigid” constant force cutting test method is either because the set workload is too large (the hanging weight is too large), causing test damage to the test saw blade, or because the set workload is too small ( If the weight of the test is too small, the potential of the test saw blade will not be exerted, and the results of the objective test will be given.
  • the current method generally uses manual measurement for important parameters such as the consumption value of the working tooth, the amount of cutting, and the timing, resulting in inaccurate measurement and conclusion.
  • the "rigid" constant force drilling and grinding are used, or the setting work is negative.
  • the load is too large (the hanging weight is too large), causing test damage to the test bit and the grinding wheel, or because the set work load is too small (the hanging weight is too small), and the potential of the test bit and the diaphragm cannot be exerted, and the objective test is given.
  • manual measurement is widely used for important parameters such as working tooth consumption value, cutting amount and timing, which leads to inaccurate measurement and conclusion.
  • the invention solves the problems of inaccurate and non-uniformity of the cutting performance of the existing diamond saw blade, the grinding performance of the diamond grinding wheel and the drilling performance of the diamond drill bit; and provides a test method for the cutting performance of the diamond saw blade, and the AC servo motor Composing an accurate, sensitive and reliable control and test system with the programmable logic controller (PLC), cleverly establishing a dynamic closed-loop servo mode of the cutting process, and timely modulating the cutting speed to stabilize the cutting load (ie, the knife thrust) and Adapt to the uneven organization of the cutting material and the variation of the performance of the saw blade working teeth, so that the saw blade is in the best state, realize intelligent cutting, and realize automatic measurement of various parameters, so as to accurately obtain the work of the diamond saw blade. performance. It not only realizes the flexible intelligent cutting test, the data is reliable, but also solves the problem of large difference in manual cutting.
  • the invention can accurately test the cutting performance of the diamond saw blade, the grinding performance of the grinding wheel and the drilling performance of the drill bit, thereby unifying the test mode of the performance of the diamond saw blade, the drill bit and the grinding wheel, forming in the industry.
  • the invention can be applied not only to diamond cutting, grinding and drilling tools, but also to performance testing of cutting, grinding and drilling tools of other materials.
  • the technical solution adopted by the present invention is:
  • a test method for cutting performance of a diamond saw blade comprising the following steps:
  • the diamond saw blade touches the cutting object, it starts timing and ranging. When cutting to the cutting tool, it immediately ends the timing and ranging.
  • the cutting load value of the diamond saw blade controlled by the servo system is 0.9M-1.1M. Intelligent cutting; that is, the cutting load value fluctuates around the set load parameter value, and the cutting thrust is flexible and constant;
  • the cutting knife depth should be greater than the thickness of the cutting object by more than 2 mm.
  • the cumulative cutting length of the diamond saw blade is not less than 10m; and the cutting time is not involved in the calculation of the sharpness when manually feeding.
  • the amount of cutting is continuously or intermittently increased during cutting to test the anti-overload performance of the diamond saw blade.
  • the invention is also applicable to the performance test of the diamond grinding wheel and the diamond drill bit.
  • the testing principle of the diamond grinding wheel and the diamond drill bit is the same as that of the diamond saw blade: that is, the set load parameter value is first obtained: the amount of the tool is manually controlled, and the tool is found.
  • a test method for grinding performance of a diamond grinding wheel characterized in that it comprises the following steps:
  • the grinding load value of the diamond grinding wheel controlled by the servo system is 0.9M-1.1M, and the cutting load is fluctuated around the set load parameter value to realize the cutting thrust flexibility constant and realize intelligent grinding;
  • the grinding wheel Before obtaining the set load parameter value, mark the circumference of the grinding wheel and use it as the measuring position of the tooth height before grinding and after grinding. Before the grinding starts, place the grinding object on the material table and fix it. Press the start button, the grinding wheel enters the automatic calibration procedure.
  • the feeding mechanism drives the diamond grinding wheel to move vertically. After touching the grinding object, the depth probe is lowered and The contact grinding object records the depth scale (Xq), while the depth probe moves to contact the grinding object, the depth probe's scale is zeroed as the infeed start position (Hq), and then the depth probe is closed to complete the automatic calibration.
  • the diamond grinding wheel is ground in the "S" shape on the grinding object; and the grinding completion time is recorded.
  • the grinding test After the grinding test completes the set cumulative grinding depth, it automatically enters the measuring procedure of the working tooth consumption and the grinding material removal amount.
  • the cutting mechanism returns to the starting position, and the feeding mechanism drives the grinding wheel to move to contact the grinding object, and records the depth scale value (Xh); at the same time, the depth probe moves, sequentially contacts the four corner points of the grinding object, and respectively records the scale value.
  • the average value of the depth probe scale value is calculated, and the depth value (Hh) of the grinding material after grinding is obtained, the depth probe is taken up, and the measurement is completed.
  • a test method for drilling performance of a diamond drill bit characterized in that it comprises the following steps:
  • the load value of the diamond drill bit is controlled by the servo system to be 0.9M-1.1M, and the fluctuation of the drilling load is constant around the set load parameter value to realize the intelligent drilling;
  • the performance of the diamond drill bit is obtained according to the drilling time, the tooth wear and the depth of the drilling.
  • the diamond drill bit is drilled to ensure that each drill hole can be drilled transversely to the steel bar.
  • the object to be drilled is tile or marble, it is necessary to examine the edge effect of the orifice.
  • the amount of the tool is increased continuously or intermittently to investigate the anti-overload capability of the drill bit.
  • the present invention has the following beneficial effects:
  • the test method of the invention solves the problem that the existing artificial propulsion cutter method is unstable; and solves the existing "rigid" constant force cutting method (weight hanging cutter, limited power (current) cutting and setting value) Cut the knife Cutting test method)
  • the problem of test damage and the inaccuracy of manual measurement parameters are not only intelligent cutting, but also automatic measurement of various parameters, so that the work of diamond saw blade, drill bit and grinding wheel can be accurately obtained. performance. Can form a unified and standardized test standard for the industry to ensure the sound development of the diamond tool industry.
  • the invention can be applied not only to diamond tools (saw blades, drills, grinding wheels, etc.) but also to performance testing of tools of other materials.
  • FIG. 1 is a logic block diagram of a servo control system of the present invention
  • FIG. 2 is a schematic view showing the structure of a front view of a fixed beam bridge type cutting test machine of the present invention
  • Figure 3 is a side view showing the structure of Figure 2;
  • Figure 4 is a logic diagram of the operating system
  • Figure 5 is a control schematic diagram of a cutting power head
  • Figure 6 is a control schematic diagram of the walking mechanism
  • Figure 7 is a flow chart of the PLC program control flow
  • Reference numerals 1, column, 2, beam, 3, tool holder, 4, driving device, 5, cutting power head, 6, drilling and grinding power head, 7, power head lifting mechanism, 8, feeding slide 9, feeding rack, 10, feeding drive mechanism, 11, electric box, 12, man-machine interface.
  • the method for testing the cutting performance of the diamond saw blade of the present invention comprises the following steps:
  • the cutting test operator must wear protective glasses and dust masks and noise-proof earplugs to work. Except for the test personnel, the saw blade should not be approached within 1.5 meters of the extension cable to ensure the safety of personnel during the test.
  • the diamond saw blade According to the function positioning of the diamond saw blade, select the appropriate cutting object; place the selected cutting object on the feeding table and set the feeding step; for the saw cutting performance test, it is to cut n times on one sheet. (The depth of the knife is the thickness of the whole plate), usually 30 times as a cycle. After each single cut, the cut sheet is moved forward by a distance (set feed step) for the next cut.
  • the specific feeding step distance is determined by the operator according to the specific material to be cut and the characteristics of the saw blade to be tested. It is better to avoid the occurrence of broken strips and minimum waste in the cutting. For the determination of the feeding step, the field The skilled person can understand and understand, and will not be described here.
  • the present invention sets the setting of the load parameter value M, and can accurately obtain the cutting performance of the diamond saw blade.
  • the diamond saw blade touches the cutting object, it starts timing and ranging, and the cutting to the cutting end immediately ends the timing and ranging; during the cutting process, the cutting load value of the diamond saw blade controlled by the servo system is 0.9M-1.1M, that is, It means that the cutting load value fluctuates around the set load parameter value, and the cutting thrust is flexible and constant, achieving intelligent grinding.
  • the servo control system of the present invention includes a display operation panel, a PLC controller and an actuator, wherein the display operation panel is electrically connected to the PLC controller, and the PLC controller is electrically connected to the interface circuit; the actuator is respectively provided with a cutting The head motor, the drill head motor, the lifting motor, the feeding motor and the cutter motor, the cutting head motor and the drilling head motor are connected by the servo drive and the interface circuit, and the lifting motor, the feeding motor and the cutter motor are respectively driven by the servo and the interface circuit.
  • the servo drive provided by the connection, the lifting motor, the feeding motor and the cutter motor receives the signal sent by the interface circuit and dynamically feeds the position signal of the lifting motor, the position signal of the feeding motor and the movement of the feeding motor to the interface circuit, and then is controlled by the PLC.
  • the controller controls to form a closed loop control.
  • all the moving mechanisms of the testing machine are driven by a servo motor, when the saw blade is in the cutting process In the middle, it is convenient, accurate and fast to measure the dynamic values of cutting current, torque, speed, speed and other parameters. It is also possible to arbitrarily select parameters such as speed, power, tooling amount, current, etc. as a precondition to cure and detect other component variations.
  • This accurate and flexible feature of this test machine is very suitable for the process technology research and development test machine, providing a powerful test and verification means for cutting, drilling and grinding tools to the high-tech field; the entire control, test and display control system As a component module, it can be flexibly configured on a variety of structural machine tools (described later) for a wide range of diamond circular saw blades (including sintered, welded, brazed), high speed steel saw blades (HSS saw blades) Cutting performance test of various cutting, drilling and grinding tools such as carbide saw blades, tungsten steel saw blades, insert alloy saw blades, grinding wheels, grinding wheels and drill bits.
  • the fixed beam bridge type cutting test machine comprises two columns 1, a beam 2, a knife holder 3, a knife driving device 4, a cutting power head 5, a drilling power head 6, and a power head lifting mechanism 7 a feeding carriage 8, a feeding gantry 9 and a feeding drive mechanism 10, wherein the two uprights 1 are fixed on a base, the cross beam 2 is laterally disposed at the top of the two uprights 1, and the traverse frame 3 passes through a straight line
  • the guide rail pair is mounted on the beam 2 and is provided with lateral running power by the cutter drive unit 4, and the cutting power head 5 and the drill grinding power head 6 are respectively mounted on the bottom surface and the front surface of the carriage holder 3, the feeding carriage 9 Installed under the cutting power head 5 and the drilling power head 6, the feeding carriage 8 is mounted on the feeding platform 9 by the feeding drive mechanism 10 and provides longitudinal feeding power by the feeding drive mechanism 10, the driving drive device 4,
  • the cutting power head 5, the drilling power head 6, the power head lifting mechanism 7 and the feeding drive mechanism 10 are respectively powered by a servo
  • the operating system logic diagram is shown in Figure 4. It includes two modes: manual debugging and automatic operation. After the test machine is started, select the manual or automatic control button to enter the corresponding working mode. Select the manual mode to debug and separately run the cutting power head motor, the knife motor, the tool holder lifting motor, the feeding motor, etc., debugging position or single operation; select the automatic mode, the machine can enter the automatic workflow according to the setting procedure: The lifting motor starts, and the tool holder moves downwards, so that the saw blade slowly approaches the working tooth height measuring device, measures and records the diameter of the saw blade before cutting, and the tool holder moves up 5mm - the feeding motor starts, and the specified step feeding is completed - Start the motor of the power head - start the motor and press the step of "fast forward - slow deceleration approach - constant force cutting - return trip - calculation display" to complete an automatic cutting process (requires cyclic cutting, press the setting get on).
  • Cutting power head mechanism Taking the power head of cutting stone as an example, high power output is required, and the output speed can be adjusted by the PLC controller.
  • the working speed range is 3000-15000 rpm with an accuracy of ⁇ 5 rpm.
  • the test machine uses a 5.5KW high-speed servo motor drive system, and the control is shown in Figure 5.
  • Input the speed information to the PLC controller through the touch screen.
  • the port (V0) of the PLC controller analog expansion module outputs 0-10V voltage value to control the analog input port (VC) of the servo drive to adjust the servo motor speed.
  • the cutting power head can select fixed power and constant speed to work.
  • the working parameters can be displayed and recorded in time. If necessary, it can be used as a modulation source to simulate the speed and power conditions of various types of user cutting machines.
  • Knife mechanism In order to ensure that the tool is not damaged when cutting, it is required to avoid impact cutting.
  • the cutting mechanism is carried out according to the three steps of “fast forward – slow deceleration approach – constant force cutting”;
  • the force cutting is realized by setting the limit value of the motor output torque.
  • the constant speed is adjusted by adjusting the rotation speed of the motor. It is this dynamic feedback cutting load (testing the current of the motor) that regulates the speed of the cutting, enabling the cutting test to achieve intelligent cutting.
  • the test machine can cut the tested saw blade under reasonable load conditions during the cutting process according to the change of the tissue hardness of the cutting object and the change of the saw blade performance until the whole test process is completed, and the whole work of the test article can be performed if necessary.
  • the full-tooth working performance is examined and the test error is smaller.
  • the cutting load it is ensured that the saw blade is cut under the set load condition constantly, which not only solves the difference problem of manual pushing of different operators, but also avoids the abnormal burning of the saw blade due to the difference in the hardness of the stone structure. It involves the two elements of "object” and "passing thrust" in "Three Elements of Cutting".
  • the saw blade with good sharpness has a small load during cutting, and has a negative value compared with the set load parameter value M.
  • the test opportunity automatically increases the cutting speed and displays a higher efficiency value; the saw blade with poor sharpness itself, The load during cutting is large, and it is positive or negative compared with the set load parameter value M.
  • the test opportunity automatically reduces the cutting speed and displays a lower efficiency value.
  • the specific control process is shown in Figure 6.
  • the specific control process is shown in Figure 6.
  • the design working torque of the servo motor is 0-10NM.
  • the set cutting torque is determined by the corresponding voltage value of the analog output port (V1) of the PLC.
  • the cutting time is automatically timed by the timer inside the PLC. When the saw blade touches the stone, the timer starts to be timed. The saw blade is cut to the tail of the stone. When it comes out of contact with the stone, the timing is stopped, and the timer is saved. In the data memory of the PLC. The cutting length is automatically counted by the counter inside the PLC and stored in the data memory.
  • the PLC program control flow chart is shown in Figure 7.
  • Pulse Equivalent (a): The rotary encoder outputs a pulse that moves the distance the servo motor moves.
  • Feeding mechanism Set the feeding size of each knife through the display operation panel (human-machine interface). When the servo motor cuts a stone, the tool holder quickly returns to the starting point and touches the sending servo motor to set the step. Stone moving size), complete a propulsion feeding. This scheduled feeding function automates the cutting test.
  • the invention skillfully establishes a dynamic closed-loop servo mode of the cutting process, adopts a closed-loop system, timely modulates the cutting speed, stabilizes the cutting load, automatically adapts to the uneven organization of the cutting material and the condition variation of the saw blade working teeth, so that the saw blade is at Work at its best and achieve intelligent cutting to get the exact performance of a diamond saw blade.
  • the AC servo motor and the programmable logic controller (PLC) form an accurate, sensitive and reliable control and test system, which not only realizes the flexible intelligent cutting test, but also solves the problem of large difference in manual cutting.
  • the invention has the advantages of scientific concept, precise design, both functionality and accuracy, wide adaptability, and a variety of variant models for cutting performance testing of various cutting, drilling and grinding tools.
  • the invention automatically tests various parameters, automatically adapts to the uneven organization of the cutting object and the condition variation of the saw blade itself, and automatically adjusts the cutting speed to avoid burning the teeth and realizes the intelligent cutting test;
  • the invention adopts a large number of cutting measurement methods of n x 100 times to eliminate random errors
  • the invention can select constant load, constant rotation speed, constant thrust (passing speed), scientifically simulate various cutting machine parameters, realize standardization test of cutting performance of cutting, drilling and grinding tools, and fill the domestic blank;
  • the present invention can arbitrarily adjust the master/slave parameters and detect the amount of change of other elements. This kind of precision and flexibility is very suitable for the research and development of test technology, providing a powerful test and verification means for cutting, drilling and grinding tools to the high-tech field;
  • the invention can establish a cutting performance database of cutting, drilling and grinding tools, and provide data support for perfect technical standards of the country and the industry;
  • the invention automatically feeds, intelligently cuts, and automatically measures, and the labor intensity of the operator is greatly reduced.
  • the test method of the invention solves the problem that the existing artificial propulsion cutter method is unstable; and solves the existing "rigid" constant force cutting method (weight hanging cutter, limited power (current) cutting and setting value)
  • the problem of the test damage of the test piece and the inaccuracy of the manual measurement parameters exist, not only realize intelligent cutting, but also realize automatic measurement of various parameters, so that the diamond saw blade, the drill bit and the grinding wheel can be accurately obtained.
  • Work performance. Can form a unified and standardized test standard for the industry to ensure the sound development of the diamond tool industry.
  • Cutting object parameters 664 granite 1200x630x20 (length x width x thickness);
  • Cutting method dry cutting; for the choice of cutting mode, those skilled in the art can understand and understand, no longer repeat here;
  • Analog cutting machine AC desktop, speed 4500 rpm, power 3.5Kw;
  • test machine start the host control and test recording system, run the machine for 5 minutes, and check whether the operation of each part of the machine is normal;
  • Load factor (preset according to the mid-range 230 specification granite saw blade) - 10;
  • the machine starts the cutting machine, the machine performs automatic calibration, and measures the height value before the cutting of the saw blade.
  • the cutting knife depth is greater than the thickness of the cutting object by more than 2 mm, which facilitates timely chip removal.
  • the cumulative cutting length of the diamond saw blade is not less than 10m; and the cutting time is not involved in the calculation of the sharpness when manually feeding.
  • the cutting object of the present invention may be concrete, ceramic tile, vitreous material or natural granite, marble, and artificial building board.
  • the test parameters of the cutting object are preferably agreed by the parties concerned, and may be taken in whole or in part from international standards, national standards or other documents related to the object to be cut; it is recommended to use concrete, ceramic tiles and natural granite building plates that meet the following criteria.
  • Remaining tail The collapse of the tail left at the end of the sheet after cutting.
  • Side effect the degree of collapse at the interface angle between the cut surface and the surface of the cut material after cutting.
  • the amount of cutting is continuously or intermittently increased during cutting to test the anti-overload performance of the diamond saw blade.
  • the invention is also applicable to the performance test of the diamond grinding wheel and the diamond drill bit.
  • the test method for the grinding performance of the diamond grinding wheel of the invention comprises the following steps:
  • dry grinding without coolant
  • wet grinding with coolant
  • the infeed device enters according to the set single infeed depth, rotates the electronic handwheel, adjusts the amount of the tool from slow to fast, and finds the maximum amount of diamond grinding wheel on the grinding object.
  • Load value K at the time; set M 0.70K-0.85K, M is the set load parameter value;
  • the grinding load value of the diamond grinding wheel controlled by the servo system is 0.9M-1.1M, that is, the grinding load value fluctuates slightly around the set load parameter value M, so that the cutting thrust is flexible and constant, and intelligent grinding is realized;
  • the tooth height consumption measurement position Place the grinding object on the material table and fix it. Press the start button, the grinding wheel enters the calibration procedure.
  • the feeding mechanism drives the grinding wheel to move vertically and records the depth scale value (Xq) after touching the grinding object. At the same time, the depth probe moves. Contact the grinding object, the depth of the depth probe is zero as the infeed start position (Hq), the depth probe is closed, and the calibration is completed;
  • the grinding load value of the diamond grinding wheel controlled by the servo system is 0.9M-1.1M, that is, the small fluctuation of the setting load parameter value M, the cutting thrust is flexible and constant; the feeding device according to the set order
  • the secondary infeed depth is fed, and the pass mechanism grinds the grinding in the "S" shape on the grinding object, and automatically records the grinding completion time. That is, in the process of grinding, the grinding wheel firstly moves from left to right in the transverse direction. When grinding to the end of the plate, the grinding wheel is longitudinally moved a certain distance and then moved laterally from right to left. The distance of longitudinal movement should be in the grinding wheel. Between 80 and 90% of the diameter of the diameter, the cycle is completed to complete the grinding. According to the grinding material, the vertical feed mechanism is set to a single feed amount. After each feed, the entire surface is ground once and then the knife is traveled. After the total set grinding depth has been reached, it is used as a grinding cycle and the time for grinding completion is recorded.
  • the cutting mechanism returns to the starting position, and the feeding mechanism drives the grinding wheel to move to contact the grinding object, and records the depth scale value (Xh); at the same time, the depth probe moves, sequentially contacts the four corner points of the grinding object, and respectively records the scale value. And on average, the depth value (Hh) of the ground material after grinding is obtained, the depth probe is taken up, and the measurement is completed.
  • the sharpness of the grinding is obtained according to the volume to be ground (the slab area * the thickness difference after grinding) and the time; the volume of the grinding object is ground and the tooth value of the grinding wheel after grinding
  • the life of the grinding wheel the formula:
  • the anti-overload test item of the grinding wheel can be increased, and the amount of cutting can be continuously or intermittently increased during grinding to investigate the anti-overload capability of the grinding wheel. This must be done after the normal grinding test is completed.
  • Grinding objects are preferably ground-finished grinding objects.
  • the materials of the grinding objects can be concrete, ceramic tiles, glass materials, natural granite, marble, and artificial building boards.
  • the test method for the drilling performance of the diamond drill bit of the present invention comprises the following steps:
  • Drilling test operators must wear protective glasses, dust masks, noise-proof earplugs and insulated waterproof boots to work; check the drilling rig, check and measure the working tooth height of the drill to be tested, and install the drill on the drilling machine, according to the test
  • the drill bit structure selects the drilling cooling mode; the drill bit speed is set according to the diameter and functional characteristics of the drill to be tested; the drilling object is selected according to the function positioning of the drill to be tested, and the mounting is ensured to be firm.
  • the load value of the diamond drill bit controlled by the servo system during the drilling process is 0.9M-1.1M;
  • the drill bit is returned, the measuring device moves to the lower side of the drill working tooth, the walking mechanism moves slowly downward, and the drill working tooth enters the measuring position, and the post-drilling work is measured.
  • the tooth height value (Xh) then the tooling mechanism returns quickly, and the measuring device returns to complete the scheduled drilling test cycle.
  • the performance of the diamond drill bit is obtained according to the drilling time, the tooth wear and the depth of the drilling.
  • the diamond drill bit is drilled to ensure that each drill hole can be cut transversely to the steel bar.
  • the object to be drilled is tile or marble, it is necessary to examine the edge effect of the orifice.
  • the drilling performance comparison test is performed on the two stone drills, in addition to the drilling performance of the drills as described above, it is necessary to drill the two drills on the same material with the same drilling parameters (1-2 ) A hole to further eliminate the interference of the material structure difference of the test object on the test.
  • Sharpness calculation of diamond bit (m/min): Accumulate the depth and time of each single hole drilling, divide the total depth by the total drilling time, that is, obtain the sharpness of the bit; calculate the life of the diamond bit (m/mm) ): Take the total depth of cumulative drilling divided by the total consumption value of the working tooth height of the drill bit, which is the life of the working tooth of the drill bit.
  • the test method of the invention solves the problem that the existing artificial propulsion cutter method is unstable; and solves the existing "rigid" constant force cutting method (weight hanging cutter, limited power (current) cutting and setting value)
  • the problem of the test damage of the test piece and the inaccuracy of the manual measurement parameters exist, not only realize intelligent cutting, but also realize automatic measurement of various parameters, so that the diamond saw blade, the drill bit and the grinding wheel can be accurately obtained.
  • Work performance. Can form a unified and standardized test standard for the industry to ensure the sound development of the diamond tool industry.
  • the invention can be applied not only to diamond tools (saw blades, drills, grinding wheels, etc.) but also to performance testing of tools of other materials.

Abstract

涉及金刚石刀具测试技术领域，提供了一种金刚石锯片切割性能的测试方法，用于解决现有金刚石刀具切割性能测试方法不准确、不统一的问题。测试方法包括如下步骤：1.获取设定负荷参数值：控制金刚石锯片的走刀量，找到金刚石锯片在切割对象上最大走刀量时的负荷值K；设定M＝0.70K-0.85K，M为设定负荷参数值；2.切割过程中通过伺服系统控制金刚石锯片的切割负荷值为0.9M-1.1M。能够实现切割三要素"机具、对象、走刀推力"的统一，并自动、准确地测试金刚石刀具的性能。

Description

金刚石锯片切割性能的测试方法 技术领域
本发明属于金刚石刀具测试技术领域，具体涉及一种金刚石锯片切割性能的测试方式。
背景技术
国标《GB/T11170超硬磨料制品金刚石圆锯片》，是我国超硬工具领域向国际标准看齐，具有一定水准的技术标准之一，但却没有对金刚石圆锯片的实际使用性能的“切割性能”这一重要特性做出定性或定量规范。
金刚石圆锯片切割性能是金刚石圆锯片的核心性能指标，锯片切割性能，是通过实际切割特定对象，在速度、负荷、消耗、留尾、边效等指标上的表现，来判定锯片切割性能的高低。通常将“机具、对象、走刀推力”简称为“切割三要素”；切割涉及的“机具、对象、走刀推力”三要素对切割测试结论影响很大，所以要尽可能做到三要素统一，才符合“同条件测试”这一基本原则。
其中的“机具”可通过统一转速来实现，“对象”通过详细约定达到统一，难点在于对“走刀推力”的控制；长期以前，各锯片制造厂商也在不断探索公正、客观、科学的切割测试方法，例如现已经有人工推进走刀法、恒力切割(砝码挂重走刀)、限功率(电流)切割和定值走刀切割测试几种方法，都不尽人意。
然而人工推进走刀法存在不稳定性的问题，与操作人员的技能、体能和经验有很大关系，就是同一机台，同一个切手，都难以实现“走刀”时的推力同一，更不用说两地测试不同切手实现“走刀”时的推力同一。
恒力切割(砝码挂重走刀)、限功率(电流)切割和定值走刀切割测试方法均属于“刚性”恒力测试方法，虽然“刚性”恒力切割方法能够解决人工推进走刀法存在随意性问题，但是这种“刚性”恒力切割测试法，要么因设置的工作负荷偏大(挂重过大)，对测试锯片造成测试损伤，要么因设置的工作负荷偏小(挂重过小)，不能发挥测试锯片的潜能，都会给出欠客观的测试结论；另外现行方法对工作齿消耗值、切割量、计时等重要参数普遍采用手动测量，导致测量和结论不准确。
对于金刚石磨轮和金刚石钻头同样存在上述问题，在金刚石钻头和金刚石磨轮在测试的过程中，都是采用“刚性”恒力钻削和磨削，要么因设置的工作负 荷偏大(挂重过大)，对测试钻头和磨轮造成测试损伤，要么因设置的工作负荷偏小(挂重过小)，不能发挥测试钻头和膜片的潜能，都会给出欠客观的测试结论，对工作齿消耗值、切割量、计时等重要参数普遍采用手动测量，导致测量和结论不准确。
综上所述，现有技术不能够对金刚石锯片、磨轮和金刚石钻头的性能进行准确的测试。随着我国金刚石锯片(磨轮、钻头)产业逐步健全，迫切需要统一、规范的测试标准，确保行业的健康发展。
发明内容
本发明为了解决现有金刚石锯片切割性能、金刚石磨轮磨削性能以及金刚石钻头钻削性能测试方法不准确、不统一的问题；而提供一种金刚石锯片切割性能的测试方法，将交流伺服电机与可编程序控制器(PLC)组成精确、灵敏、可靠的控制、测试系统，巧妙地建立切割过程动态闭环伺服模式，适时调制走刀速度，既稳定切割负荷(即走刀推力)，又自适应切割材料组织不均和锯片工作齿自身性能不均的条件变化，使锯片处于最佳状态工作，实现智能切割，并对各种参数实现自动测量，从而能够准确获取金刚石锯片的工作性能。既实现柔性智能切割测试，数据可靠，又解决了人工推切差异大的难题。
相比于现有的测试方法，能够准确的测试金刚石锯片的切割性能、磨轮的磨削性能以及钻头的钻削性能，从而统一金刚石锯片、钻头和磨轮性能的测试方式，在行业内形成一个测试标准。本发明不仅能够应用于金刚石切、磨、钻刀具，还能够应用于其他材质的切、磨、钻刀具的性能测试。
为解决上述技术问题，本发明所采用的技术方案是：
一种金刚石锯片切割性能的测试方法，包括如下步骤：
1、启动切割机进行低速空运转确保切割机运转正常；
2、根据锯片结构，选择干式切割(不加冷却液)或者湿式切割(加冷却液)；
3、将金刚石锯片安装在切割机上，并保证金刚石锯片旋向与切割机主轴旋向相同；
4、根据金刚石锯片功能定位，选择适宜的切割对象；将选择的切割对象放置于送料台上，并设定送料步距；
5、启动切割机，设备进行自动定标，测量锯片工作齿切前高度值；然后进行手动进刀，由慢至快调节走刀速度，找到金刚石锯片的最大走刀量时的负荷值K；设 定M＝0.70K-0.85K，M为设定负荷参数值；
6、金刚石锯片接触到切割对象的同时开始计时和测距，切割至出刀即刻结束计时和测距；切割过程中通过伺服系统控制金刚石锯片的切割负荷值为0.9M-1.1M，实现智能切割；即是说切割负荷值围绕设定负荷参数值波动，实现切割推力柔性恒定；
7、自动测量工作齿消耗值、切割量以及自动计时；根据切割的长度和切割的时间计算出金刚石锯片的锋利度；根据切割的长度和切割时消耗的金刚石锯片齿高计算出金刚石锯片的使用寿命。
为了避免堵屑干扰测试，所述切割吃刀深度需大于切割对象厚度大于2mm。
金刚石锯片的测试累计切割长度不小于10m；并且手动进刀时切割时间不参与锋利度的计算。
若对两款以上的金刚石锯片切割性能做对比测试时，应当在同一切割对象上进行同条件切割测试一定刀数。
所述切割对象为瓷砖和大理石时，需要考察留尾与边效。
在切割中持续或间歇性加大走刀量以测试金刚石锯片的抗过载性能。
本发明同样适用于金刚石磨轮、金刚石钻头的性能测试，金刚石磨轮和金刚石钻头的测试原理与金刚石锯片的测试原理相同：即，先获取设定负荷参数值：手动控制刀具的走刀量，找到刀具在测试对象上最大走刀量时的负荷值K，设定，M＝0.70K-0.85K，M为设定负荷参数值；然后在测试过程中通过伺服系统控制刀具的切割负荷为0.9M-1.1M；最后根据获得测试数据计算出刀具的性能。
一种金刚石磨轮磨削性能的测试方式，其特征在于：包括以下步骤：
1、自动定标，测量磨轮工作齿磨前高度值；
2.获取设定负荷参数值：控制金刚石磨轮的走刀量，找到金刚石磨轮在磨削对象上最大走刀量时的负荷值K；设定M＝0.70K-0.85K，M为设定负荷参数值；
3.磨削过程中通过伺服系统控制金刚石磨轮的磨削负荷值为0.9M-1.1M，围绕设定负荷参数值波动，实现切割推力柔性恒定，实现智能磨削；
4.自动测量相关参数，根据磨削对象的被磨削的体积和时间获得金刚石磨轮的磨削锋利度；根据磨削对象被磨削的体积和磨轮磨削后齿高的消耗值得到金刚石磨轮的寿命。
在获取设定负荷参数值之前，在磨轮圆周上做标记，并以此作为磨削前、磨削后齿高消耗测量位。在磨削开始之前，将磨削对象安放于料台上并固定，按启动键，磨轮进入自动定标程序，进刀机构带动金刚石磨轮垂直移动并在接触到磨削对象后，深度探头放下并接触磨削对象记录深度标尺(Xq)，同时深度探头移动接触磨削对象，深度探头的标尺归零作为进刀起始位(Hq)，然后收起深度探头完成自动定标。
在磨削过程中金刚石磨轮在磨削对象上面按照“S”字形循环走刀磨削；并记录磨削完成的时间。
磨削试验完成设定的累计磨削深度后，自动进入工作齿消耗和磨削材料去除量的测量程序。走刀机构回到起始位，进刀机构带动磨轮移动接触到磨削对象后，记录深度标尺值(Xh)；同时深度探头移动，依次接触磨削对象的四个角点，分别记录标尺值并计算出深度探头标尺值的平均值，得到磨削后的磨削材料去除深度值(Hh)，深度探头收起，测量完成。
一种金刚石钻头钻削性能的测试方式，其特征在于：包括以下步骤：
1.自动定标，测量钻头工作齿钻前高度值；
2.获取设定负荷参数值：控制金刚石钻头的走刀量，找到金刚石钻头在钻削对象上最大走刀量时的负荷值K；设定M＝0.70K-0.85K，M为设定负荷参数值；
3.钻削过程中通过伺服系统控制金刚石钻头的负荷值为0.9M-1.1M，围绕设定负荷参数值波动，实现钻削推力柔性恒定，实现智能钻削；
4.根据钻进的时间、齿高磨耗和钻进的深度获得金刚石钻头的性能。
在获取设定负荷参数值前，在钻头圆周上进行标记，并以此作为钻削前、钻削后齿高消耗测量位。
钻削对象为钢筋混凝土预制件时，金刚石钻头进行试钻的时候保证每一个钻试孔都能够横向钻切到钢筋。
若钻削对象为瓷砖、大理石类时，需考察孔口边效。
在钻削的过程中持续或间隙性加大走刀量以考察钻头的抗过载能力。
与现有技术相比，本发明具有以下有益效果：
本发明的测试方法解决了现有人工推进走刀法存在不稳定的问题；同时解决了现有的“刚性”恒力切割方法(砝码挂重走刀、限功率(电流)切割和定值走刀切 割测试方法)存在的对试品的测试损伤问题和人工测量参数不准确的问题，不仅实现智能切割，并能对各种参数实现自动测量，从而能够准确获取金刚石锯片、钻头、磨轮的工作性能。能为行业形成一个统一、规范的测试标准，确保金刚石刀具行业的健全发展。
本发明不仅能够应用于金刚石刀具(锯片、钻头、磨轮等)，还能够应用于其他材质的刀具的性能测试。
附图说明
图1为本发明的伺服控制系统的逻辑框图；
图2为本发明的固定梁桥式切割测试机的主视图结构示意图；
图3为图2的侧视图结构示意图；
图4为操作系统逻辑图；
图5为切割动力头的控制原理图；
图6为走刀机构的控制原理图；
图7为PLC程序控制流图图；
附图标记：1、立柱，2、横梁，3、走刀架，4、走刀驱动装置，5、切割动力头，6、钻磨动力头，7、动力头升降机构，8、送料滑座，9、送料台架，10、送料驱动机构，11、电箱，12、人机交汇界面。
具体实施方式
下面结合实施例对本发明作进一步的描述，所描述的实施例仅仅是本发明一部分实施例，并不是全部的实施例。基于本发明中的实施例，本领域的普通技术人员在没有做出创造性劳动前提下所获得的其他所用实施例，都属于本发明的保护范围。
本发明的金刚石锯片切割性能的测试方法，包括如下步骤：
切割试验操作人员必须戴上防护眼镜和防尘口罩及防噪耳塞方可作业。除测试人员外,锯片旋向延长线1.5米以内不得有人靠近，确保测试时的人员安全。
1、启动切割机进行低速空运转确保切割机运转正常；一般情况下启动切割机低速空运转5分钟，走刀机构同时运行，确保各个运动机构均能够正常工作；
2、根据锯片结构，选择干式切割(不加冷却液)或者湿式切割(加冷却液)；
3、将金刚石锯片安装在切割机上，并保证金刚石锯片旋向与切割机主轴旋向相同；
4、根据金刚石锯片功能定位，选择适宜的切割对象；将选择的切割对象放置于送料台上，并设定送料步距；对锯片切割性能测试，是在一张板材上做n次切割(吃刀深度为全穿板材厚度)，通常以30次为一个周期，每单次切割完成后，被切割板材纵向前移一段距离(设定的送料步距)，供下刀次切割。具体的送料步距移动距离，由操作人员依据具体被切材料不同和被测锯片特性而定，兼顾切割中不产生断条和材料最小浪费为宜，对于送料步距的确定，本领域的技术人员都能明白和理解，在此不再赘述。
5、启动切割机，先进行手动进刀，走刀量由小逐渐增大，找到金刚石锯片的最大走刀量时的负荷值K；设定M＝0.70K-0.85K，M为设定负荷参数值。
本发明的设定负荷参数值M的设定，能够避免过负荷而烧齿，又能够防止负荷过小而影响锯片的应有性能发挥。因此，本发明设定负荷参数值M的设定，能够精准的获得金刚石锯片的切割性能。
6、金刚石锯片接触到切割对象的同时开始计时和测距，切割至出刀即刻结束计时和测距；切割过程中通过伺服系统控制金刚石锯片的切割负荷值为0.9M-1.1M，即是说切割负荷值围绕设定负荷参数值波动，实现切割推力柔性恒定，实现智能磨削。
7、自动测量工作齿消耗值、切割量以及自动计时；根据切割的长度和切割的时间计算出金刚石锯片的锋利度；根据切割的长度和切割时消耗的金刚石锯片齿高计算出金刚石锯片的使用寿命。本发明能够对切割参数能够进行自动检测和计算，提高了数据的精确性。
结合附图1，本发明的伺服控制系统包括显示器操作面板、PLC控制器和执行机构，其中显示操作面板与PLC控制器电连接，PLC控制器电连接有接口电路；执行机构分别配设有切割头电机、钻磨头电机、升降电机、送料电机和走刀电机，切割头电机和钻磨头电机经伺服驱动与接口电路连接，升降电机、送料电机和走刀电机分别经伺服驱动与接口电路连接，升降电机、送料电机和走刀电机配设的伺服驱动接受接口电路输送出的信号并且将升降电机的位置信号、送料电机的位置信号和走刀电机动态反馈给接口电路，再由PLC控制器进行控制，从而形成一个闭环控制。
本发明由于测试机各运动机构全部采用伺服电机驱动，当锯片在切割过程 中，可方便、准确、快捷测量切割电流、扭矩、转速、走刀速度等参数的动态值。还可任意选择转速、功率、走刀量、电流等参数充当前提条件固化，检测其它要素变动量。本测试机这种精确不失灵活的特点非常适宜担当工艺技术研发试验用机，为切、钻、磨类工具向高新技术领域拓展提供了有力的测试验证手段；整个控制、测试、显示操控系统作为部件模块，可灵活配置于多种结构机床(详见后述)，用于宽泛规格的金刚石圆锯片(含烧结型、焊接型、钎焊型)、高速钢锯片(HSS锯片)、硬质合金锯片、钨钢锯片、镶齿合金锯片、砂轮、磨轮、钻头等多种切、钻、磨工具的切割性能测试。
本发明一实施例的固定梁桥式切割测试机：包括两个立柱1、横梁2、走刀架3、走刀驱动装置4、切割动力头5、钻磨动力头6、动力头升降机构7、送料滑座8、送料台架9和送料驱动机构10，其中所述两个立柱1固定在底座上，所述横梁2横向设置在两个立柱1的顶部，所述走刀架3通过直线导轨副安装在横梁2上并由走刀驱动装置4提供横向走刀动力，所述切割动力头5和钻磨动力头6分别安装在走刀架3的底面和正面，所述送料台架9安装在切割动力头5和钻磨动力头6的下方，送料滑座8通过送料驱动机构10安装在送料台架9上并由送料驱动机构10提供纵向送料动力，所述走刀驱动装置4、切割动力头5、钻磨动力头6、动力头升降机构7和送料驱动机构10分别由伺服电机提供动力，并且所有伺服电机均和电箱11连接，电箱11配设有人机交汇界面12。
下面以固定梁桥式切割测试机为例，对本发明的控制过程作进一步描述。其中伺服控制系统的逻辑框图如图1所示。
操作系统逻辑图如图4所示，包括手动调试和自动工作两种模式，测试机启动后，选择手动或自动控制按钮进入相应工作模式。选择手动模式，可调试和单独运行切割动力头电机、走刀电机、刀架升降电机、送料电机等，调试位置或单项运行；选择自动模式，机器可根据设定程序，进入自动工作流程：即，升降电机启动，带动刀架下移，让锯片缓慢趋近工作齿高测量装置，测量并记录锯片切前直径，刀架上移5mm——送料电机启动，完成规定步距送料——动力头电机启动——走刀电机启动，按“快进——减速缓慢趋近——恒力切割——回程——计算显示”的步骤完成一次自动切割过程(需循环切割，则按设定进行)。
切割动力头机构：以切割石材的动力头为例，要求大功率输出，且能够通过PLC控制器调节输出转速，工作转速范围为3000-15000rpm，精度±5rpm。测试机选用5.5KW的高速伺服电机驱动系统，控制如图5所示。通过触摸屏输入转速信息到PLC控制器，经过运算，PLC控制器模拟量扩展模块的端口(V0)输出0-10V电压值，去控制伺服驱动器的模拟量输入端口(VC)，达到调整伺服电机转速的目的。本切割动力头可以选择定功率和定转速工作，工作参数可适时显示和记录，必要时可以充当调制信源，方便模拟各类用户切割机转速和功率条件。
走刀机构：为了保证切入时刀具不受损伤，要求避免冲击切入，切割时走刀机构按“快进——减速缓慢趋近——恒力切割”三步骤进行；在切割石材过程中要求恒力切割，是靠对电机输出转矩设定限值实现，当负荷发生变化时，靠变动电机的转速以调整推力来恒定负荷。正是这种动态反馈切割负荷(测试走刀电机电流)，调控走刀速度的方式，使切割测试实现了智能切割。测试机可以在切割过程中，根据切割对象的组织硬度变化和锯片性能变化使被测锯片始终保持在合理负荷条件下切割，直至完成整个测试过程，若有必要可以将测试品的整个工作层消耗完毕，考察全齿工作性能，测试误差更小。通过控制切割负荷，保证锯片恒定在设定负荷条件下切割，既解决了不同操作手人工推切的差异难题，又避免了石材组织硬度差异导致锯片非正常烧齿。涉及《切割三要素》中的“对象”和“走刀推力”两个要素)。
本身锋利度好的锯片，切割中的负荷较小，与设定负荷参数值M比较呈负值，测试机会自动加大走刀速度，显示较高效率值；本身锋利度差的锯片，切割中的负荷较大，与设定负荷参数值M比较正负，测试机会自动减少走刀速度，显示较低效率值。
具体控制过程如图6所示：具体控制过程见图6，伺服电机的设计工作转矩为0-10NM，设定的切割转矩是由PLC的模拟量输出端口(V1)的相应电压值去控制伺服驱动器的转矩模拟量端口(VC)。切割时间是通过PLC内部的定时器进行自动计时，当锯片接触石材时即触发定时器开始计时，锯片切割至石材尾部，脱离与石材接触时停止计时，并将定时器的当将值保存在PLC的数据存储器中。切割长度是通过PLC内部的计数器对伺服电机的旋转编码器进行自动计数，并保存在数据存储器中。PLC程序控制流程图如图7。
切割长度在PLC中的计算公式：
切割长度(L)＝脉冲当量(a)x脉冲个数(c)
脉冲当量(a)：旋转编码器输出一个脉冲，走刀伺服电机移动的距离。
脉冲个数(c)：走刀伺服电机切割石材时，旋转编码器输出的脉冲个数。
单刀切割效率(m/s)见以下公式：
单刀切割效率η(m/s)＝切割长度L(m)/切割时间τ(s)。
送料机构：通过显示操作面板(人机交汇界面)设定每刀送料尺寸，当走刀伺服电机切割完一刀石材后，走刀架快速回到起点，并触发送料伺服电机按设定步距(石材移动尺寸)，完成一次推进送料。这种按预定程序送料功能，使切割测试实现了自动化。
本发明巧妙地建立切割过程动态闭环伺服模式，通过闭环系统，适时调制走刀速度，稳定切割负荷，自动适应切割材料组织不均和锯片工作齿自身性能不均的条件变化，使锯片处于最佳状态工作，实现智能切割，从而能够获取金刚石锯片的准确性能。应用现代信息成组理念，将交流伺服电机与可编程序控制器(PLC)组成精确、灵敏、可靠的控制、测试系统，既实现柔性智能切割测试，又解决了人工推切差异大的难题。
本发明构思科学，设计精到，功能性与准确性兼具，适应范围广，有多款变型机种，用于各类切、钻、磨工具的切割性能测试。
本发明自动测试各项参数，自动适应切割对象组织不均和锯片自身性能不均的条件变化，自动调整走刀速度来避免烧齿，实现智能切割测试；
本发明采用n x100次的大量切割测量方式，消除随机误差；
本发明可以选择恒负荷、恒转速、恒推力(走刀速度)，科学模拟各种切割机具参数，实现切、钻、磨工具切割性能标准化测试，填补了国内空白；
本发明可任意调整主/从参数，检测其它要素的变化量。这种精确不失灵活的特点，非常适宜担当工艺技术研发试验用机，为切、钻、磨类工具向高新技术领域拓展提供了有力的测试验证手段；
本发明可建立切、钻、磨工具切割性能数据库，为国家、行业完善技术标准提供数据支撑；
本发明自动送料、智能切割、自动测量，操作员劳动强度大为降低。
本发明的测试方法解决了现有人工推进走刀法存在不稳定的问题；同时解决了现有的“刚性”恒力切割方法(砝码挂重走刀、限功率(电流)切割和定值走刀切割测试方法)存在的对试品的测试损伤问题和人工测量参数不准确的问题，不仅实现智能切割，并能对各种参数实现自动测量，从而能够准确获取金刚石锯片、钻头、磨轮的工作性能。能为行业形成一个统一、规范的测试标准，确保金刚石刀具行业的健全发展。
下面以测试锯片切割性能为例，简要说明操作步骤：
待测样品型号：G230x7x2.5x25中档花岗石切割片；
切割对象参数：664花岗石1200x630x20(长x宽x厚)；
切割方式：干式切割；对于切割方式的选择，本领域的技术人员都能明白和理解，在此不再赘述；
模拟切割机具：交流台式机，转速4500rpm，功率3.5Kw；
操作步骤：
1.打开测试机电源，启动主机控制和测试记录系统，空运行机器5分钟；同时检查机器各部运行是否正常；
2.确认机器功能正常后，将测试锯片安装在切割动力头主轴上，压紧法兰盘，关好护罩门。
3.将石板放置于送料台上，同时验证气动夹紧功能有效；
4.按照要求模拟交流台式机，应采用定转速测试。在测试机人机界面中，设置相关切割参数：设定转速——3000rpm；
负荷系数(按中档230规格花岗石类锯片预设)——10；
进刀深度——25mm；
走刀量——自动；
单刀切割长度——650mm；
送料步距——7；
切割模式——A；
设定负荷参数值—
总切割刀数——100；
5.启动切割机，机器进行自动定标，测量锯片工作齿切前高度值；
6.寻找被测锯片最大负荷值K：启动主轴，转动电子手轮，让走刀机构“快进——缓慢趋近——切割”三步骤运行，当锯齿接触石材后逐渐加大走刀量直至锯片齿刃出现火圈立刻停止走刀，出现火圈时的负荷就是该锯片的最大负荷值K，设定M＝0.70K-0.85K，输入设定负荷值后，将“切割模式”设为B，进入自动切割程序。
7.切割测试切割刀数满足设定的100刀后，即停止切割，机器自动计算出该锯片的锋利度和寿命，完成一个切割测试周期。
8.验证参数输入正确后，按启动键操作界面设5个窗口，分别是：
a.测试切、钻、磨工具切割效率动态显示曲线窗；显示每刀实际切割效率；
b.测试切、钻、磨工具参数窗；显示被测切钻磨工具几何参数；
c.手动调试窗，可方便设置测试参数或调试机器；
d.切割测试参数设置/显示窗。
9、根据切割的长度和切割的时间计算出金刚石锯片的锋利度；根据切割的长度和切割时消耗的金刚石锯片高度计算出金刚石锯片的使用寿命。锋利度：单位时间试样被切进的长度(单位：M/min)；寿命：消耗的单位锯片工作齿的高度切断的材料长度(单位：M/mm)。
为了避免堵屑干扰测试，所述切割吃刀深度大于切割对象厚度大于2mm，便于及时排屑。
金刚石锯片的测试累计切割长度不小于10m；且手动进刀时切割时间不参与锋利度的计算。
其中，本发明的切割对象可为混凝土、陶瓷砖、玻璃质材料或天然花岗石、大理石、以及人造建筑板材等材料。切割对象测试参数最好由有关方商定，可以全部或部分地取自与切割对象有关的国际标准、国家标准或其他文件；推荐选用符合下列标准的混凝土、陶瓷砖和天然花岗石建筑板材作为切割对象：
GB 50204-2015《混凝土结构工程质量验收规范》；
GB/T 4100-2015《陶瓷砖》；
GB/T 18601-2009《天然花岗石建筑板材》。
若对两款以上的金刚石锯片进行切割性能测试对比时，应当在同一张板材上切割5-10刀，进一步排除石材因素的干扰。
所述切割对象为瓷砖和大理石时，需要考虑考察留尾与边效。留尾：切割后在板材末尾端上留下的崩尾。边效：切割后被切割材料切面与表面交界角上的崩缺程度。
在切割中持续或间歇性加大走刀量以测试金刚石锯片的抗过载性能。
本发明同样适用于金刚石磨轮、金刚石钻头的性能测试，金刚石磨轮和金刚石钻头的测试原理与金刚石锯片的测试原理相同：即，启动机器进行自动定标，测量锯片工作齿切前高度值；寻找最大负荷值K：启动主轴，转动电子手轮，由慢至快调节走刀速度，找到金刚石磨轮、钻头在切割对象上最大走刀量时的负荷值K；设定M＝0.70K-0.85K，其中M为设定负荷参数值；然后在测试过程中通过伺服系统控制刀具的切割负荷为0.9M-1.1M；即伺服系统控制刀具的负荷围绕设定负荷参数值M小幅波动，实现推力柔性恒定，最后根据获得测试数据计算出刀具的性能。
本发明的金刚石磨轮磨削性能的测试方式，包括以下步骤：
磨削试验操作人员必须戴上防护眼镜和防尘口罩及防噪耳塞方可作业。
启动磨机低速空运转5分钟(走刀机构同时运行)，确保各个部件的正常运转。
根据磨轮结构，选择干式磨削(不加冷却液)或湿式磨削(加冷却液)。
1.自动定标，测量磨轮工作齿磨削前的高度值；
2.获取设定负荷参数值：进刀装置按照设定的单次进刀深度进到，转动电子手轮，由慢至快调节走刀量，找到金刚石磨轮在磨削对象上最大走刀量时的负荷值K；设定M＝0.70K-0.85K，M为设定负荷参数值；
3.磨削过程中通过伺服系统控制金刚石磨轮的磨削负荷值为0.9M-1.1M，即磨削负荷值围绕设定负荷参数值M小幅波动，实现切割推力柔性恒定，实现智能磨削；
4.自动检测工作齿消耗值、自动测算磨削量、自动计时，根据磨削对象的被磨削的体积和时间获得金刚石磨轮的磨削锋利度；根据磨削对象被磨削的体积和磨轮磨削后齿高的消耗值得到金刚石磨轮的寿命。
具体操作：
1.自动定标，测量磨轮工作齿磨前高度值。
在获取设定负荷参数值之前，在磨轮圆周上标记一个点，并以此点作为磨 前、磨后齿高消耗测量位。将磨削对象安放于料台上并固定，按启动键，磨轮进入定标程序，进刀机构带动磨轮垂直移动并在接触到磨削对象后，记录深度标尺值(Xq)；同时深度探头移动接触磨削对象，深度探头的标尺归零作为进刀起始位(Hq)，深度探头收起，定标完成；
2.获取设定负荷参数值M，启动主轴旋转，进刀装置按照设定的单次进刀深度进刀，转动电子手轮，由慢至快调节走刀速度，找到金刚石磨轮在磨削对象上最大走刀量时的负荷值K；设定M＝0.70K-0.85K，其中M为设定负荷参数值；
3.磨削过程中通过伺服系统控制金刚石磨轮的磨削负荷值为0.9M-1.1M，即围绕着设定负荷参数值M小幅波动，实现切割推力柔性恒定；进刀装置按照设定的单次进刀深度进刀，走刀机构在磨削对象上按照“S”字形逐行循环走刀磨削，并自动记录磨削完成的时间。即，在磨削的过程中，磨轮先从左至右进行横向走刀，磨削到板材端头时，纵向移动磨轮一定距离再从右至左进行横向走刀，纵向移动的距离应当在磨轮直径宽度的80—90％之间，如此循环走刀完成磨削。根据磨削材料，设定垂直进刀机构单次进刀量，每一次进刀后需将整个表面磨削一次再行进刀。累计达到设定磨削总深度后，作为一个磨削周期，并记录磨削完成的时间。
4.磨削试验完成设定的累计磨削深度后自动进入工作齿消耗和磨削材料去除量的测量程序。走刀机构回到起始位，进刀机构带动磨轮移动接触到磨削对象后，记录深度标尺值(Xh)；同时深度探头移动，依次接触磨削对象的四个角点，分别记录标尺值并平均，得到磨削后的磨削材料去除深度值(Hh)，深度探头收起，测量完成。根据磨削对象被磨削的体积(石板面积*磨前磨后测量厚度差值)和时间得到磨削锋利度；根据磨削对象被磨削的体积和磨轮磨削后齿高的消耗值获得磨轮的寿命，计算公式：
磨削去除材料量计算(Vm)：(Hq-Hh)*L*W(单位：cm3)
磨轮齿高消耗计算(X)：Mh-Mq-(Hq-Hh)(单位：mm)
磨轮锋利度计算(cm3/min)：磨削去除材料量/磨削总时间
磨轮寿命计算(cm3/mm)：磨削去除材料量/齿高消耗值
如果对两款石材类磨轮做磨削性能的比对测试，除按前述分别测试各张磨轮的磨削性能外，还需用同一磨削参数将2件磨轮在同一件材料上磨削1-2个周期，进一步排除磨试对象材质结构差异的干扰。
必要时，可增加磨轮的抗过载试验项，磨削中持续或间歇性加大走刀量，以考察磨轮的抗过载能力。此项必须在正常磨削测试完成后进行。
磨削对象优选选用边缘规整的磨削对象，磨削对象的材质可以为混凝土、陶瓷砖、玻璃材质、天然花岗石、大理石、以及人造建筑板材等材料。
本发明的金刚石钻头钻削性能的测试方式，包括以下步骤：
钻削试验操作人员必须戴上防护眼镜、防尘口罩、防噪耳塞及绝缘防水靴方可作业；检查钻机，检查并测量待测钻头工作齿高度，将钻头安装在钻机上拧紧，根据待测试钻头结构选择钻削冷却方式；根据待测试钻头直径和功能特性设置钻头转速；根据待测试钻头功能定位选择钻削对象，并确保安放牢固。
1.获取设定负荷参数值：手动控制金刚石钻头的走刀量，找到金刚石钻头在钻削对象上最大走刀量时的负荷值；设定M＝0.70K-0.85K，其中K为手动进刀时金刚石钻头最大走刀量时的负荷值，M为钻进测试时的设定负荷参数值；
2.钻削过程中通过伺服系统控制金刚石钻头的负荷值为0.9M-1.1M；
3.根据钻进的时间、齿高磨耗和钻进的深度获得金刚石钻头的性能。
具体步骤为：
1.自动测量钻前、钻后工作齿高，即：在获取设定负荷参数值之前，需先行定标，完成钻试周期后，自动测量钻头工作齿消耗值，评估钻头寿命。具体为：安装旋紧钻头，在钻头圆周上标记一个点，并以此点作为钻前、钻后齿高消耗测量位。按启动键，测量装置移动至钻头工作齿下方，走刀机构缓慢向下移动，让钻头工作齿进入测量位，测得钻前工作齿高值(Xq)，然后走刀机构快速回程，测量装置回位。
2.获取设定负荷参数值M，启动钻机，拨动电子轮调节钻头走刀速度，按“快进——缓慢趋近——钻进”三步骤运行，钻进中逐渐加快走刀量，以增大钻进负荷，找到钻头最大走刀量时的负荷值K；设定M＝0.70K-0.85K，其中M为设定负荷参数值；在钻削的过程中，通过伺服系统控制金刚石钻头的负荷值为0.9M-1.1M，即围绕设定负荷参数值M小幅波动，实现切割推力柔性恒定。
3.完成预定的钻削测试量后(钻孔数)，钻头回位，测量装置移动至钻头工作齿下方，走刀机构缓慢向下移动，让钻头工作齿进入测量位，测得钻后工作齿高值(Xh)，然后走刀机构快速回程，测量装置回位，完成预定钻试周期。
4.根据钻进的时间、齿高磨耗和钻进的深度获得金刚石钻头的性能。
钻削对象为钢筋混凝土预制件时，金刚石钻头进行试钻的时候保证每一个钻试孔都能够横向切钻到钢筋。
若钻削对象为瓷砖、大理石类时，需考察孔口边效。
必要时，可增加钻头的抗过载试验项，钻削中持续或间歇性加大走刀量，以考察钻头的抗过载能力；此项必须在正常钻削测试完成后进行。
如果对两款石材类钻头做钻削性能的比对测试，除按前述分别测试钻头的钻削性能外，还需用同一钻削参数将2支钻头在同一件材料上钻削(1-2)个孔，进一步排除钻试对象材质结构差异对测试的干扰。
金刚石钻头的锋利度计算(m/min)：累计各单孔钻削的深度和时间，将总深度除以总钻削时间，即得到该钻头的锋利度；金刚石钻头的寿命计算(m/mm)：取累计钻削的总深度除以钻头工作齿高度总消耗值，即为该钻头工作齿的寿命。
本发明的测试方法解决了现有人工推进走刀法存在不稳定的问题；同时解决了现有的“刚性”恒力切割方法(砝码挂重走刀、限功率(电流)切割和定值走刀切割测试方法)存在的对试品的测试损伤问题和人工测量参数不准确的问题，不仅实现智能切割，并能对各种参数实现自动测量，从而能够准确获取金刚石锯片、钻头、磨轮的工作性能。能为行业形成一个统一、规范的测试标准，确保金刚石刀具行业的健全发展。
本发明不仅能够应用于金刚石刀具(锯片、钻头、磨轮等)，还能够应用于其他材质的刀具的性能测试。

Claims (10)

  1. 金刚石锯片切割性能的测试方法，其特征在于：包括以下步骤：
    a.获取设定负荷参数值：控制金刚石锯片的走刀量，找到金刚石锯片在切割对象上最大走刀量时的负荷值K；设定M＝0.70K-0.85K，M为设定负荷参数值；
    b.切割过程中通过伺服系统控制金刚石锯片的切割负荷值为0.9M-1.1M；
    c.根据切割的长度和切割的时间计算出金刚石锯片的锋利度；根据切割的长度和切割时消耗的金刚石锯片齿高计算出金刚石锯片的使用寿命。
  2. 一种金刚石磨轮磨削性能的测试方式，其特征在于：包括以下步骤：
    a.获取设定负荷参数值：控制金刚石磨轮的走刀量，找到金刚石磨轮在磨削对象上最大走刀量时的负荷值K；设定M＝0.70K-0.85K，M为设定负荷参数值；
    b.磨削过程中通过伺服系统控制金刚石磨轮的磨削负荷值为0.9M-1.1M；
    c.根据磨削对象的被磨削的体积和时间获得金刚石磨轮的磨削锋利度；根据磨削对象被磨削的体积和磨轮磨削后齿高的消耗值得到金刚石磨轮的寿命。
  3. 一种金刚石钻头钻削性能的测试方式，其特征在于：包括以下步骤：
    a.获取设定负荷参数值：控制金刚石钻头的走刀量，找到金刚石钻头在钻削对象上最大走刀量时的负荷值K；设定M＝0.70K-0.85K，M为设定负荷参数值；
    b.钻削过程中通过伺服系统控制金刚石钻头的负荷值为0.9M-1.1M；
    c.根据钻进的时间、齿高磨耗和钻进的深度获得金刚石钻头的性能。
  4. 根据权利要求2所述的金刚石磨轮磨削性能的测试方法，其特征在于，在获取负荷参数值之前，在磨轮圆周上做标记，并以此作为磨削前、磨削后齿高消耗测量位。
  5. 根据权利要求2所述的金刚石磨轮磨削性能的测试方法，其特征在于，在磨削开始之前，将磨削对象安放于料台上并固定，控制金刚石磨轮接触到磨削对象后，同时深度探头放下并接触磨削对象，深度探头的标尺归零作为进刀起始位，然后收起深度探头；在磨削过程中金刚石磨轮在磨削对象上面按照“S”字形循环走刀磨削，并记录磨削完成的时间。
  6. 6.根据权利要求5所述的金刚石磨轮磨削性能的测试方法，其特征在于，磨削完成后再次将深度探头放下并接触磨削对象，同时移动深度探头，依次接触磨削对象上的多个点并计算出深度探头标尺值的平均值，从而获得磨削对象去除深度值。
  7. 根据权利要求3所述的金刚石钻头钻削性能的测试方式，其特征在于：在获取设定负荷参数值前，在钻头圆周上进行标记，并以此作为钻削前、钻削后齿高消耗测量位。
  8. 根据权利要求7所述的金刚石钻头钻削性能的测试方法，其特征在于，钻削对象为钢筋混凝土预制件时，金刚石钻头进行试钻的时候保证每一个钻试孔都能够横向钻切到钢筋。
  9. 根据权利要求3所述的金刚石钻头钻削性能的测试方法，其特征在于，若钻削对象为瓷砖、大理石类时，需考察孔口边效。
  10. 根据权利要求3所述的金刚石钻头钻削性能的测试方法，其特征在于，在钻削的过程中持续或间隙性加大走刀量以考察钻头的抗过载能力。
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