Based on the analysis of the mechanism of wire tension control by using torque motors in the multi-wire saw machining process, some mathematical models of a tension control system are studied, and an adaptive algo- ri...Based on the analysis of the mechanism of wire tension control by using torque motors in the multi-wire saw machining process, some mathematical models of a tension control system are studied, and an adaptive algo- rithm is designed for controlling the wire tension. In this algorithm of tension control, the rotation speeds and waving angle of motors are measured and fed back to the controller, and the NLMS（ normalized least mean squares） algorithm is used to calculate the adaptive correction value and control the wire tension accurately. The computer simulation results in Matlab software validate the high accuracy for controlling the system of the wire tension with the NLMS algorithm in the multi-wire saw machining process.展开更多
Great attention has been paid on fabricating diamond wire by using the brazing diamond because of its strong chemical bonding strength and controllability of grits distribution. Although several serving performances o...Great attention has been paid on fabricating diamond wire by using the brazing diamond because of its strong chemical bonding strength and controllability of grits distribution. Although several serving performances of brazed diamond wire have been reported, seldom do these studies refer to its process characteristics. Sawing performances of a brazed diamond wire are investigated and compared with those of a sintered diamond wire on a wire saw machine. The surface topographies of beads selected from the two wires are micro observed before sawing. The sawing tests are carried out in constant feed rate feeding（CFF） and constant normal force feeding（CNFF）. In CFF test, sawing force, power, and the cut depths of positions on contact curve are measured. Then, coupled with the observations of beads topographies, sawing force and its ratio, relations of power against material removal rate, and contact curve linearity are compared and discussed. In CNFF test, the sawing rates of the two wires are investigated. The results indicate that the brazed wire performs with lower sawing force（less 16% of tangential force and 28% of normal force）, more energy efficiency（nearly one-fifth of sawing power is saved）, at a higher sawing rate （the rate is doubled） and with better contact curve linearity as compared with the sintered wire. This proposed research experimentally evaluates the sawing performances of brazed diamond wire from the aspect of process parameters, which can provide a basis for popularizing the brazed diamond wire.展开更多
An experimental study was carried out to quantitati ve ly evaluate the loads acting on the diamond grits during circular sawing of two kinds of typical granite with diamond segmented saw blade. Measurements were mad e...An experimental study was carried out to quantitati ve ly evaluate the loads acting on the diamond grits during circular sawing of two kinds of typical granite with diamond segmented saw blade. Measurements were mad e of the horizontal and vertical force components and the consumed power in order to obtain the tangential and the normal force components. The temperatures at the diamond-granite contact zone were measured using a foil thermocouple. T he measurement, together with the net sawing power, was subsequently used to est imate the energy partition to the granite by a temperature matching technique. B ased on the energy partition values, the temperatures at individual cutting poin ts were estimated using an analytical model. SEM was used to follow the topograp hies of worn diamond segments. The average force acting on each diamond grit was found to be only 4% of the diamond compressive strength measured by a static me thod. The strength disparity of diamond grits and the random protrusion of grits beyond bond matrix should be significant factors in accounting for the wear of diamond grits. The wear of diamond grits was also found to be closely related to the high temperatures generated at individual cutting points and the pop-outs of diamonds from the bond matrix might be mainly attributed to the heat conducte d to the segments.展开更多
As a starting point in equipment manufacturing,sawing plays an important role in industrial production.Intelligent manufacturing equipment is an important carrier of intelligent manufacturing technologies.Due to the b...As a starting point in equipment manufacturing,sawing plays an important role in industrial production.Intelligent manufacturing equipment is an important carrier of intelligent manufacturing technologies.Due to the backwardness of intelligent technology,the comprehensive performance of sawing equipments in China is obviously different from that in foreign countries.State of the art of advanced sawing equipments is investigated along with the technical bottleneck of sawing machine tool manufacturing,and a new industrial scheme of replacing turning-milling by sawing is described.The key technologies of processing-measuring integrated control,multi-body dynamic optimization,the collaborative sawing network framework,the distributed cloud sawing platform,and the self-adapting service method are analyzed;with consideration of the problems of poor processing control stableness,low single machine intelligence level,no on-line processing data service and active flutter suppression of sawing with wide-width and heavy-load working conditions.Suggested directions for further research,industry implementation,and industry-research collaboration are provided.展开更多
The building of a large-scale external-target experiment, abbreviated as CEE, in the cooling storage ring at the Heavy Ion Research Facility in Lanzhou has been planned. The CEE is a multi-purpose spectrometer that wi...The building of a large-scale external-target experiment, abbreviated as CEE, in the cooling storage ring at the Heavy Ion Research Facility in Lanzhou has been planned. The CEE is a multi-purpose spectrometer that will be used for various studies on heavy-ion collisions. A multi-wire drift chamber(MWDC) array is the forward tracking detector of the CEE. In this work, GEANT4 simulations were performed for the MWDC forward tracking array with a focus on the track reconstruction algorithm. Combined with the time of flight information,particle identification is achieved. The residue is about 30 μm, while the tracking efficiency is higher than 90%with the current redundancy. In addition, a prototype of the forward tracking system using three MWDCs was assembled and tested using a high-energy proton beam. The firing efficiency of the detector and the reconstruction accuracy of the prototype were derived. The track residue for the protons at about 400 MeV/c is better than 300 μm, meeting the requirements of the CEE. Suggestions for improving the performance of the forward tracking system are given.展开更多
Diamond grits are indispensable for sawing granite or concrete.Each year about 1 000 tons of diamond grits are consumed for such purposes.In all cases,mono crystalline diamond is used.However, polycrystalline grits(po...Diamond grits are indispensable for sawing granite or concrete.Each year about 1 000 tons of diamond grits are consumed for such purposes.In all cases,mono crystalline diamond is used.However, polycrystalline grits(polygrits) are generally better performed than mono grits as abrasives.For example,poly grits of cubic boron nitride(e.g.Borazon(?) CBN-550 of Diamond Innovations) can cut faster and they last longer than mono grits(e.g.Borazon(?) CBN-500). Polygrits of alumina(e.g.Cubitron(?) of 3M) also out perform by far glassy grits(e.g.white alumina).For diamond superabrasives,micron polygrits formed by shock waves may polish as fast as mono grits of the same size,but without causing as much scratches due to the presence of smaller sintered grains.The improved performance of poly grits is attributed to their ability to micro chipping that renews the sharp cutting corners from time to time.By contrast,mono grits tend to round off at low cutting force or macro fracture at high cutting force,so they may lose the cutting ability rapidly. For sawing granite with mesh sizes 40/50 or coarser,poly grits of diamond have not been available until recently.In this research,we have made polygrits in mini cube with sizes of 18/20,20/25,and 30/40.Turbo grinders and wire saws were made by brazing both mono grits and polygrits on steel substrates.Cutting performance on granite demonstrated that grinding speed was faster with turbo grinder,and the surface finish was smoother with wire saw for poly grits than mono ones. Polygrits and mono grits of diamond were mixed for comparison(upper left).Polygrits of mini cubes were brazed on the pearl of a wire saw(upper right).Mono diamond grits were brazed on a turbo grinder(bottom diagrams ).展开更多
The diamond wire-sawing process was developed to cut granite in both quarries and block processing plants.In this paper,swarf was collected from different areas along the sawing arc when sawing three granites.The part...The diamond wire-sawing process was developed to cut granite in both quarries and block processing plants.In this paper,swarf was collected from different areas along the sawing arc when sawing three granites.The particle size distribution and the morphology of the swarf were investigated systematically,along with the swarf formation mechanism in sawing.Granite swarf formation was dominated by transgranular fractures based on the morphology of sawn granite chips and the analysis of sawn chip size.A long cutting arc increased the movement among the swarf,tool,and workpiece,thereby inducing a secondary fracture in the sawn chip.展开更多
Physical-chemical characteristics of the band sawing dusts regarding to recovery of pure silicon from them were investigated.The experimental results show 50vol%-60vol% amorphous phases exist in the dusts,which is mos...Physical-chemical characteristics of the band sawing dusts regarding to recovery of pure silicon from them were investigated.The experimental results show 50vol%-60vol% amorphous phases exist in the dusts,which is mostly amorphous silica.The as-received saw dusts are found to form hard agglomerates of larger than 50 microns in diameter.The iron-based inclusions collected by magnets are found to match well with the band saw material in XRD patterns.Weight loss in heating was observed by thermal gravity tests,up to 900 ℃,presumably due to reaction of the amorphous silica with carbon contaminant in the dusts.The saw dusts were variously treated to examine their physical-chemical responses,and the results were also presented.展开更多
Four wear modes and four wear mechanisms of diamonds in sawblades are identified in a study of varied segments damaged in field operation of sawing hard stone. The four wear mechanisms are impactshearing, fatiguing, p...Four wear modes and four wear mechanisms of diamonds in sawblades are identified in a study of varied segments damaged in field operation of sawing hard stone. The four wear mechanisms are impactshearing, fatiguing, pullingout and thermal effects. Surface erosion is the result of thermal effects, while impactshearing and fatiguing lead to macro and microfracture, and pullingout results in wholesale dislodgement of diamonds provided the inequality Fn>M/(μλδ) is satisfied.展开更多
In this study,magnetic abrasives were obtained by crushing and sieving sintered iron-silicon carbide(Fe-SiC)composites.Fe and SiC powders with different mesh numbers were pre-compacted using different pressures and th...In this study,magnetic abrasives were obtained by crushing and sieving sintered iron-silicon carbide(Fe-SiC)composites.Fe and SiC powders with different mesh numbers were pre-compacted using different pressures and then sintered at various temperatures and with different holding times.The dispersion uniformity of the SiC powder was improved through surface modification using polyethylene glycol(PEG)300.The resulting magnetic abrasives were characterized in terms of phase composition,density,relative permeability,and microstructure;this was followed by a comprehensive analysis to reveal the optimal processing parameters.The ideal combination of process parameters for preparing SiC magnetic-abrasive grains for the magnetic induction-wire sawing process was obtained,which are preparation load of 60 kN,a SiC mesh number of 1,500,a sintering temperature of 1100℃,and a holding time of 4 h.展开更多
The present paper gives a numerical simulation of hot sawing process by using elastic- plastic finite element method. The simulation is carried out for the moment from the beginning of deformation to the local yield i...The present paper gives a numerical simulation of hot sawing process by using elastic- plastic finite element method. The simulation is carried out for the moment from the beginning of deformation to the local yield in work piece. In order to treat the work hardening on deformation resistance, a correction of stress based on deformation rate is taken into consideration. The calculation results shows, there are two stress peaks both on the lower and upper sides ahead of the tooth tip during the elastic press stage, in which the displacement of tooth is below 0.735*10-6 cm. Following the push of saw tooth and rise of saw load, metal at the corner of filing reaches the yield point and a local plastic area appears,where metal shapes new filing part towards the free surface under the extrusion forces. Meanwhile the stress peaks ahead of tooth tip initial also yield regions. The displacement of saw tooth is between 0.735*10-6cm and 1.274*10-6cm in this stage. With the further push of the saw tooth, metal bounded to tooth tip is torn under the combination of tensile and sheer stress. The slide of metal and its local plastic flow form the extension of filing. Then the saw load rises no longer and static sawing procedure continues.展开更多
The surface profile behavior of workpieces sawn has been investigated. Six species were sawn under the condi-tion of four different kinds of cutting speed by the band saw. The real surface profile of a sawn workpiecc ...The surface profile behavior of workpieces sawn has been investigated. Six species were sawn under the condi-tion of four different kinds of cutting speed by the band saw. The real surface profile of a sawn workpiecc is composed of twosections, which arc the additivity of the waviness of filtered wave and roughness curve. The roughness of center line avernge aswell as amplitude decrease with the increasing of cutting speed for different kinds of species used in the experiment.展开更多
Grains in the slurry can be brought into cutting zone by steel wire with a certain speed to achieve the purpose of removing the workpiece material in the free abrasive wire sawing machining. Because its own of multi- ...Grains in the slurry can be brought into cutting zone by steel wire with a certain speed to achieve the purpose of removing the workpiece material in the free abrasive wire sawing machining. Because its own of multi- strands characteristics, we use it to replace the steel wire to do slicing experiment. In this paper, multi-strands wire is made by seven metal wires and has many grooves on its surface. Compared with steel wire, it can carry more grains into cutting zone which is conducive to improving the slicing efficiency. We do some comparative slic- ing experimcnts by applying multi-strands wire （~b0.25 mm） and steel wire （~b0.25 mm） to cut optical glass （K9）. The results show that slicing efficiency and the surface roughness of the workpiece sliced by using multi-strands wire are better than that by using steel wire. but the kerf width of the former is wider than that of the latter in the same experimental conditions.展开更多
基金supported by the National Natural Science Fundproject (50775207)Key Laboratory of E & M (Zhejiang University of Technology) Open Fund project (2009EP017)
文摘Based on the analysis of the mechanism of wire tension control by using torque motors in the multi-wire saw machining process, some mathematical models of a tension control system are studied, and an adaptive algo- rithm is designed for controlling the wire tension. In this algorithm of tension control, the rotation speeds and waving angle of motors are measured and fed back to the controller, and the NLMS（ normalized least mean squares） algorithm is used to calculate the adaptive correction value and control the wire tension accurately. The computer simulation results in Matlab software validate the high accuracy for controlling the system of the wire tension with the NLMS algorithm in the multi-wire saw machining process.
基金supported by National Natural Science Foundation of China(Grant Nos. 51235004, 51105148, 51175194)Program for Changjiang Scholars and Innovative Research Team in University of China(Grant No. IRT1063)
文摘Great attention has been paid on fabricating diamond wire by using the brazing diamond because of its strong chemical bonding strength and controllability of grits distribution. Although several serving performances of brazed diamond wire have been reported, seldom do these studies refer to its process characteristics. Sawing performances of a brazed diamond wire are investigated and compared with those of a sintered diamond wire on a wire saw machine. The surface topographies of beads selected from the two wires are micro observed before sawing. The sawing tests are carried out in constant feed rate feeding（CFF） and constant normal force feeding（CNFF）. In CFF test, sawing force, power, and the cut depths of positions on contact curve are measured. Then, coupled with the observations of beads topographies, sawing force and its ratio, relations of power against material removal rate, and contact curve linearity are compared and discussed. In CNFF test, the sawing rates of the two wires are investigated. The results indicate that the brazed wire performs with lower sawing force（less 16% of tangential force and 28% of normal force）, more energy efficiency（nearly one-fifth of sawing power is saved）, at a higher sawing rate （the rate is doubled） and with better contact curve linearity as compared with the sintered wire. This proposed research experimentally evaluates the sawing performances of brazed diamond wire from the aspect of process parameters, which can provide a basis for popularizing the brazed diamond wire.
基金ProjectsupportedbytheNationalNaturalScienceFoundationofChina (NSFC ) (No .5 0 1 75 0 3 0 ) ,theEducationDepartmentofFujianProvinceinChina (No .JA0 0 2 3 6) ,andtheNaturalScienceFoundationofFujianProvinceinChina (No .F0 1 1 0 0 0 2 )
文摘An experimental study was carried out to quantitati ve ly evaluate the loads acting on the diamond grits during circular sawing of two kinds of typical granite with diamond segmented saw blade. Measurements were mad e of the horizontal and vertical force components and the consumed power in order to obtain the tangential and the normal force components. The temperatures at the diamond-granite contact zone were measured using a foil thermocouple. T he measurement, together with the net sawing power, was subsequently used to est imate the energy partition to the granite by a temperature matching technique. B ased on the energy partition values, the temperatures at individual cutting poin ts were estimated using an analytical model. SEM was used to follow the topograp hies of worn diamond segments. The average force acting on each diamond grit was found to be only 4% of the diamond compressive strength measured by a static me thod. The strength disparity of diamond grits and the random protrusion of grits beyond bond matrix should be significant factors in accounting for the wear of diamond grits. The wear of diamond grits was also found to be closely related to the high temperatures generated at individual cutting points and the pop-outs of diamonds from the bond matrix might be mainly attributed to the heat conducte d to the segments.
基金Supported by Natural Science Foundation of China(Grant No.51775501)Natural Science Foundation of Zhejiang Province,China(Grant Nos.LZ21E050003,LR16E050001,LY17E050004).
文摘As a starting point in equipment manufacturing,sawing plays an important role in industrial production.Intelligent manufacturing equipment is an important carrier of intelligent manufacturing technologies.Due to the backwardness of intelligent technology,the comprehensive performance of sawing equipments in China is obviously different from that in foreign countries.State of the art of advanced sawing equipments is investigated along with the technical bottleneck of sawing machine tool manufacturing,and a new industrial scheme of replacing turning-milling by sawing is described.The key technologies of processing-measuring integrated control,multi-body dynamic optimization,the collaborative sawing network framework,the distributed cloud sawing platform,and the self-adapting service method are analyzed;with consideration of the problems of poor processing control stableness,low single machine intelligence level,no on-line processing data service and active flutter suppression of sawing with wide-width and heavy-load working conditions.Suggested directions for further research,industry implementation,and industry-research collaboration are provided.
基金supported by the National Basic Research Program of China(973)(No.2015CB856903)the National Science Foundation of China(No.U1332207)
文摘The building of a large-scale external-target experiment, abbreviated as CEE, in the cooling storage ring at the Heavy Ion Research Facility in Lanzhou has been planned. The CEE is a multi-purpose spectrometer that will be used for various studies on heavy-ion collisions. A multi-wire drift chamber(MWDC) array is the forward tracking detector of the CEE. In this work, GEANT4 simulations were performed for the MWDC forward tracking array with a focus on the track reconstruction algorithm. Combined with the time of flight information,particle identification is achieved. The residue is about 30 μm, while the tracking efficiency is higher than 90%with the current redundancy. In addition, a prototype of the forward tracking system using three MWDCs was assembled and tested using a high-energy proton beam. The firing efficiency of the detector and the reconstruction accuracy of the prototype were derived. The track residue for the protons at about 400 MeV/c is better than 300 μm, meeting the requirements of the CEE. Suggestions for improving the performance of the forward tracking system are given.
文摘Diamond grits are indispensable for sawing granite or concrete.Each year about 1 000 tons of diamond grits are consumed for such purposes.In all cases,mono crystalline diamond is used.However, polycrystalline grits(polygrits) are generally better performed than mono grits as abrasives.For example,poly grits of cubic boron nitride(e.g.Borazon(?) CBN-550 of Diamond Innovations) can cut faster and they last longer than mono grits(e.g.Borazon(?) CBN-500). Polygrits of alumina(e.g.Cubitron(?) of 3M) also out perform by far glassy grits(e.g.white alumina).For diamond superabrasives,micron polygrits formed by shock waves may polish as fast as mono grits of the same size,but without causing as much scratches due to the presence of smaller sintered grains.The improved performance of poly grits is attributed to their ability to micro chipping that renews the sharp cutting corners from time to time.By contrast,mono grits tend to round off at low cutting force or macro fracture at high cutting force,so they may lose the cutting ability rapidly. For sawing granite with mesh sizes 40/50 or coarser,poly grits of diamond have not been available until recently.In this research,we have made polygrits in mini cube with sizes of 18/20,20/25,and 30/40.Turbo grinders and wire saws were made by brazing both mono grits and polygrits on steel substrates.Cutting performance on granite demonstrated that grinding speed was faster with turbo grinder,and the surface finish was smoother with wire saw for poly grits than mono ones. Polygrits and mono grits of diamond were mixed for comparison(upper left).Polygrits of mini cubes were brazed on the pearl of a wire saw(upper right).Mono diamond grits were brazed on a turbo grinder(bottom diagrams ).
文摘The diamond wire-sawing process was developed to cut granite in both quarries and block processing plants.In this paper,swarf was collected from different areas along the sawing arc when sawing three granites.The particle size distribution and the morphology of the swarf were investigated systematically,along with the swarf formation mechanism in sawing.Granite swarf formation was dominated by transgranular fractures based on the morphology of sawn granite chips and the analysis of sawn chip size.A long cutting arc increased the movement among the swarf,tool,and workpiece,thereby inducing a secondary fracture in the sawn chip.
基金Funded by the LDK Solar(TC-NU-0004)the Science & Technology Project of Education Department of Jiangxi Province(No.GJJ10034)
文摘Physical-chemical characteristics of the band sawing dusts regarding to recovery of pure silicon from them were investigated.The experimental results show 50vol%-60vol% amorphous phases exist in the dusts,which is mostly amorphous silica.The as-received saw dusts are found to form hard agglomerates of larger than 50 microns in diameter.The iron-based inclusions collected by magnets are found to match well with the band saw material in XRD patterns.Weight loss in heating was observed by thermal gravity tests,up to 900 ℃,presumably due to reaction of the amorphous silica with carbon contaminant in the dusts.The saw dusts were variously treated to examine their physical-chemical responses,and the results were also presented.
文摘Four wear modes and four wear mechanisms of diamonds in sawblades are identified in a study of varied segments damaged in field operation of sawing hard stone. The four wear mechanisms are impactshearing, fatiguing, pullingout and thermal effects. Surface erosion is the result of thermal effects, while impactshearing and fatiguing lead to macro and microfracture, and pullingout results in wholesale dislodgement of diamonds provided the inequality Fn>M/(μλδ) is satisfied.
基金supported by Talents Introduction Research Projects of NBPT[Grant Number RC201807]the National Nature Science Foundation of China(NSFC)[Grant Number 51475427].
文摘In this study,magnetic abrasives were obtained by crushing and sieving sintered iron-silicon carbide(Fe-SiC)composites.Fe and SiC powders with different mesh numbers were pre-compacted using different pressures and then sintered at various temperatures and with different holding times.The dispersion uniformity of the SiC powder was improved through surface modification using polyethylene glycol(PEG)300.The resulting magnetic abrasives were characterized in terms of phase composition,density,relative permeability,and microstructure;this was followed by a comprehensive analysis to reveal the optimal processing parameters.The ideal combination of process parameters for preparing SiC magnetic-abrasive grains for the magnetic induction-wire sawing process was obtained,which are preparation load of 60 kN,a SiC mesh number of 1,500,a sintering temperature of 1100℃,and a holding time of 4 h.
文摘The present paper gives a numerical simulation of hot sawing process by using elastic- plastic finite element method. The simulation is carried out for the moment from the beginning of deformation to the local yield in work piece. In order to treat the work hardening on deformation resistance, a correction of stress based on deformation rate is taken into consideration. The calculation results shows, there are two stress peaks both on the lower and upper sides ahead of the tooth tip during the elastic press stage, in which the displacement of tooth is below 0.735*10-6 cm. Following the push of saw tooth and rise of saw load, metal at the corner of filing reaches the yield point and a local plastic area appears,where metal shapes new filing part towards the free surface under the extrusion forces. Meanwhile the stress peaks ahead of tooth tip initial also yield regions. The displacement of saw tooth is between 0.735*10-6cm and 1.274*10-6cm in this stage. With the further push of the saw tooth, metal bounded to tooth tip is torn under the combination of tensile and sheer stress. The slide of metal and its local plastic flow form the extension of filing. Then the saw load rises no longer and static sawing procedure continues.
文摘The surface profile behavior of workpieces sawn has been investigated. Six species were sawn under the condi-tion of four different kinds of cutting speed by the band saw. The real surface profile of a sawn workpiecc is composed of twosections, which arc the additivity of the waviness of filtered wave and roughness curve. The roughness of center line avernge aswell as amplitude decrease with the increasing of cutting speed for different kinds of species used in the experiment.
基金National Natural Science Foundation of China(No.51075367)Natural Science Foundation of Zhejiang Province(No.Y1090931)
文摘Grains in the slurry can be brought into cutting zone by steel wire with a certain speed to achieve the purpose of removing the workpiece material in the free abrasive wire sawing machining. Because its own of multi- strands characteristics, we use it to replace the steel wire to do slicing experiment. In this paper, multi-strands wire is made by seven metal wires and has many grooves on its surface. Compared with steel wire, it can carry more grains into cutting zone which is conducive to improving the slicing efficiency. We do some comparative slic- ing experimcnts by applying multi-strands wire （~b0.25 mm） and steel wire （~b0.25 mm） to cut optical glass （K9）. The results show that slicing efficiency and the surface roughness of the workpiece sliced by using multi-strands wire are better than that by using steel wire. but the kerf width of the former is wider than that of the latter in the same experimental conditions.
