Study on Electroplated Diamond Wire Saw Development and Wire Saw Wear Analysis

Abstract

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.

Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

“…Considering that both the service life and the working efficiency of the brazed diamond grits are superior to the sintered ones, the former was chosen as subject of this work [ 5 ]. The primary wear form of the diamond beads is pulled-out grits, and the breakages of the diamond wire were mainly due to fatigue failure [ 6 , 7 ]. Therefore, the planning of the cutting parameters is crucial to diamond wire saw cutting.…”