The physical model of fixed-abrasive diamond wire-sawing monocrystalline silicon was founded to analyze the elastic deformation of the wire, supposing that every grit was connected to the surface of the wire by a spring. Ignoring lateral vibration of the wire, the geometrical model of wire-sawing was founded; the average cut depth of single grit was calculated theoretically. Based the indentation fracture mechanics and investigations on brittle-ductile transition of machining monocrystalline silicon, the removal mechanism and surface formation was studied theoretically. It shows that in the case of wire-sawing velocity of 10m/s or higher, infeed velocity of 0.20mm/s and diamond grain size of 64μm or smaller, the chip formation and material removal is in a brittle regime mainly, but the silicon wafer surface formation is sawed in a ductile regime. The size of the abrasives, the wire-saw velocity and infeed velocity can influence the sawing process obviously.
Development of high performance diamond impregnated wire is the key of application for fixed-abrasive wire sawing technology. In this paper, some experimental studies were done for development of electroplated diamond wire saw by employing the bright nickel bath. The wire saw electroplating process was developed, the effects of cathode current density and time at tack-on stage on diamond grits density and adhesion between saw matrix and plating coating were discussed. The wire saw cutting experiments were carried out for analysis the used wire wear using the scanning electron microscope (SEM). The experimental results show the optimum tack-on current density to obtain the wire saw with good abrasive distribution and adhesion is 1.5~2.0A/dm2, and the time of pre-plating, tack-on and buildup is 6, 8~10 and 18min in turn. Diamond wire saw wear includes coating wear and grain-abrasion, and the primary wear form is grits pulled-out.
Because its advantages of lower manufacture cost and higher slicing quality, the resin bonded diamond wire saw is supposed to be used widely in the future for slicing hard-brittle materials such as silicon crystal. In this paper, based on the research of the resin bonded diamond wire saw manufacturing technology and slicing process, we select Φ0.2mm SWPB piano string as core wire, 20-30m (800#) diamond grain as abrasive, liquid phenolic resin mixed with epoxy resin as adhesive, the nanometer powders as additive to improve the adhesive holding strength of abrasive grains and heat resistance. By orthogonal experiment, we find the resin bonded diamond wire saw has optimizing performance as the additives is 10% in adhesive, the epoxy resin is 30% in resin, the diamond is 50% in whole mixed material. Slicing experiments proves that the resin bonded diamond wire saw manufactured in this study has better slicing performance. The failure forms of the resin bonded diamond wire saw are wear out of resin adhesive, falling off of diamond grains and the partial peeling off of the resin bond.
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