Taglio di precisione di materiali magnetici con filo diamantato: 2 Dati di prova mm
Sample testing for a European client (Company P) · Ring diamond wire cutting process
Panoramica
This report documents precision slicing of magnetic material using a ring diamond wire cutting system. The evaluation covers equipment and wire selection, cutting methodology, process parameters, and the resulting thickness uniformity, l'accuratezza dimensionale, surface quality and edge integrity of the sliced parts. Test results indicate that a gantry-type ring diamond wire machine, oil-based cooling and lubrication, and appropriately matched process parameters deliver stable, high-precision slicing of magnetic material.
1. Test Specimen
| Parametro | Valore |
|---|---|
| Materiale | Magnetic material |
| Durezza | approx. 6–7 Mohs |
| Dimensioni del pezzo | 60 mm × 26.0 mm × 3.0 millimetro |
| Target slice dimensions | 2.0 mm × 26.0 mm × 3.0 millimetro |
2. Selezione di apparecchiature e filo
Attrezzatura: ESO-GM. In view of the hard-brittle characteristics of magnetic material and the requirement to slice at a 2 mm di spessore, Ensoll selected the ESO-GM gantry-type ring diamond wire cutting system with a top-down vertical feed. The gantry configuration maintains a stable wire trajectory and slice dimensional accuracy.
Refrigerante: taglio a base di olio. a. It improves lubrication and heat dissipation in the contact zone between the diamond wire and the magnetic material, reduces friction resistance and localised heat accumulation during cutting, and limits fluctuation in cutting load and its effect on the material. Questo aiuta a sopprimere scheggiature, micro-cracking and surface damage.
Filo: completamente placcato. È stato selezionato un filo diamantato completamente placcato. La costruzione placcata migliora la resistenza dell'adesione tra i grani abrasivi diamantati e il nucleo del filo e fornisce una distribuzione dei grani più uniforme. Questo mantiene un tasso di rimozione del materiale continuo e stabile, riduce l'estrazione dei grani e l'usura del filo, e contribuisce a una minore scheggiatura, micro-cracking and surface damage when slicing magnetic material.
3. Metodo di taglio e vantaggi delle attrezzature
Configurazione di taglio a portale. La struttura a portale fornisce elevata rigidità complessiva e stabilità di funzionamento. The top-down vertical feed helps keep the diamond wire trajectory stable and reduces the influence of changes in cutting force on kerf position and dimensional accuracy in the magnetic material. The machine is equipped with a mist-extraction system that promptly removes mist generated during cutting.
Controllo intelligente della tensione. Il sistema regola la tensione del filo diamantato in tempo reale in base alle condizioni di taglio e supporta sia la modalità a tensione costante sia quella a tensione variabile, mantenendo il filo in funzionamento stabile. Stable wire tension reduces fluctuation in the cutting trajectory and limits localised uneven loading and the risk of wire breakage caused by tension variation, which in turn reduces defects in the magnetic material.
Memoria della rottura del filo. Se il filo diamantato si rompe o la macchina si ferma in modo anomalo, Il sistema registra automaticamente la posizione attuale di lavorazione e lo stato operativo associato. Dopo la sostituzione del filo, cutting resumes from the recorded position, reducing dimensional deviation and material loss caused by re-positioning and repeat machining. This improves the continuity of magnetic material slicing and lowers the risk of repeated cutting.
Telaio in ghisa monopezzo ad alta rigidità. The one-piece cast iron frame provides high structural stiffness and vibration resistance, reducing the effect of machine vibration and structural deformation on the wire trajectory during machining. For a hard-brittle material such as magnetic material, the high-rigidity frame helps damp vibration and fluctuation in cutting force during the cut and keeps the diamond wire running stably.
4. Parametri di processo e metodo di raffreddamento
| Parametro | Valore |
|---|---|
| Diametro del filo (millimetro) | 0.35 × 1880 |
| Velocità di percorrenza del filo (mm/min) | 2 |
| Larghezza di taglio (millimetro) | 60 |
| Tensione del filo (N) | 140 |
| Velocità del filo (m/s) | 26 |
| Tempo di piegamento del filo (s) | 60 |
5. Prestazioni di taglio e risultati
5.1 Dati del test TTV (Unità: millimetro)
Variazione dello spessore totale (TTV) è stato misurato utilizzando una griglia a nove punti, Metodo di misurazione dello spessore a doppia sonda su un banco a depressione. The measurement was applied to magnetic material slices produced by ring diamond wire cutting. Before measurement the instrument was thermally stabilised and calibrated against a standard thickness block. Lo spessore nominale della fetta era 2.000 millimetro.
| Campione | Letture dello spessore a nove punti | Tmax | Tmin | TTV |
|---|---|---|---|---|
| S01 | 1.992, 1.996, 1.998 1.995, 2.000, 2.003 1.997, 2.004, 2.006 |
2.006 | 1.992 | 0.014 |
| S02 | 1.988, 1.993, 1.997 1.995, 2.001, 2.004 1.999, 2.006, 2.008 |
2.008 | 1.988 | 0.020 |
| S03 | 1.985, 1.990, 1.994 1.992, 1.998, 2.002 1.996, 2.004, 2.009 |
2.009 | 1.985 | 0.024 |
| S04 | 1.994, 1.997, 2.000 1.996, 2.001, 2.004 1.999, 2.005, 2.007 |
2.007 | 1.994 | 0.013 |
| S05 | 1.989, 1.994, 1.997 1.993, 1.999, 2.003 1.996, 2.005, 2.010 |
2.010 | 1.989 | 0.021 |
Valutazione. Nine-point grid measurement was applied to five magnetic material slices. TTV values were 0.014, 0.020, 0.024, 0.013 e 0.021 millimetro, spanning 0.013–0.024 mm across the batch, with a mean TTV of approximately 0.018 mm on a 2.000 spessore nominale di mm. The results confirm good thickness uniformity in magnetic material slicing.
5.2 Dati sulla tolleranza dello spessore (Unità: millimetro)
Thickness tolerance was derived from the nine-point thickness data, using 2.000 mm come spessore nominale. The positive and negative thickness deviation were calculated at each measurement position and the results from all five samples were aggregated. La massima deviazione positiva, maximum negative deviation and overall deviation range were then determined to evaluate thickness consistency.
| Campione | Spessore medio | Deviazione dello spessore |
|---|---|---|
| S01 | 1.999 | −0.001 |
| S02 | 1.999 | −0.001 |
| S03 | 1.997 | −0.003 |
| S04 | 2.000 | 0.000 |
| S05 | 1.998 | −0.002 |
| Deviazione positiva massima | — | +0.010 millimetro |
| Deviazione negativa massima | — | −0.015 mm |
| Banda di tolleranza dello spessore | — | ±0.0125 mm |
Valutazione. Rispetto a uno spessore nominale di 2.000 millimetro, the five slices showed mean thicknesses of 1.997–2.000 mm, with small average deviations across the batch. Over all measurement points the thickness deviation ranged from −0.015 mm to +0.010 millimetro, with a maximum absolute deviation of 0.015 millimetro.
5.3 Dati di rugosità superficiale Ra (Unità: μm)
Rugosità superficiale (Ra) was measured by stylus profilometry on the magnetic material slices after ring diamond wire cutting. Sono state prese posizioni rappresentative di misura al centro e su entrambi i lati lungo la faccia finale di taglio, i dati del profilo superficiale sono stati acquisiti con un profilometro a stilo, e il parametro di rugosità Ra è stato registrato in ogni posizione.
| Campione | Centre | Mid-left | Mid-right | Ra medio |
|---|---|---|---|---|
| S01 | 0.52 | 0.56 | 0.49 | 0.52 |
| S02 | 0.48 | 0.53 | 0.50 | 0.50 |
| S03 | 0.61 | 0.66 | 0.58 | 0.62 |
| S04 | 0.46 | 0.51 | 0.48 | 0.48 |
| S05 | 0.55 | 0.59 | 0.53 | 0.56 |
Valutazione. Mean Ra across the five samples ranged from 0.48 A 0.62 μm, con tutte le letture individuali comprese tra 0.46 e 0.66 μm. The narrow spread across the three measurement positions on each slice indicates a uniform surface finish along the cut face.
5.4 Dati sulla scheggiatura dei bordi (Unità: μm)
La scheggiatura dei bordi è stata quantificata tramite immagini ottiche su un microscopio di utensili. Specimen edges were cleaned before measurement and the magnification and measurement scale of the instrument were calibrated. The slice edge was then inspected under the microscope, identifiable chipping defects were located and measured at four points per sample, and the maximum value was retained.
| Campione | Point 1 | Point 2 | Point 3 | Point 4 | Max. scheggiature |
|---|---|---|---|---|---|
| S01 | 4.2 | 5.1 | 4.8 | 5.6 | 5.6 |
| S02 | 3.8 | 4.6 | 5.2 | 4.4 | 5.2 |
| S03 | 5.6 | 6.8 | 7.5 | 6.2 | 7.5 |
| S04 | 3.5 | 4.1 | 4.6 | 3.9 | 4.6 |
| S05 | 4.9 | 5.7 | 6.3 | 5.2 | 6.3 |
Valutazione. Toolmaker’s microscope inspection of the five magnetic material slices gave maximum chipping values of 5.6, 5.2, 7.5, 4.6 e 6.3 μm, with an overall maximum of 7.5 μm. S04 showed the best edge integrity and S03 the largest chipping at 7.5 μm.
6. Conclusione
The good results obtained in this high-precision slicing trial of magnetic material stemmed mainly from the combined effect of a purpose-built cutting machine, the cooling and lubrication method, and correctly matched process parameters. Magnetic material is relatively hard with a degree of brittleness. During ring diamond wire cutting the abrasive grains act continuously on the material surface, and material removal is affected by cutting load, wire running condition and the machining parameters.
Attrezzatura. An ESO-GM gantry-type ring diamond wire cutting system was used. The gantry structure provides high overall rigidity and running stability and gives reliable mechanical support for workpiece clamping and continuous wire travel. Stable motion and feed control keep the diamond wire on the programmed path throughout the cut.
Cooling and lubrication. È stato utilizzato olio da taglio come mezzo di raffreddamento e lubrificazione. During cutting the diamond wire remains in continuous contact with the workpiece and the abrasive grains grind the material continuously, generando calore da attrito nella zona di contatto. Cutting oil improves lubrication at the cutting interface, carries away part of the cutting heat, and reduces friction between the wire and the workpiece, which helps limit thermal effects and edge damage.
Parametri di processo. Velocità del filo, feed rate and other key parameters were matched to the hardness, brittleness and target slice thickness of the magnetic material. I parametri sono stati impostati per mantenere stabile il movimento del filo e la rimozione continua del materiale, avoiding feed rates high enough to raise cutting load, or a mismatch between wire speed and feed rate that would degrade slice quality.
Complessivamente. Taken together with slice dimensional accuracy, thickness tolerance, rugosità superficiale (Ra) and cut-edge quality, the combination of the ESO-GM gantry cutting machine, oil-based cooling and lubrication, and appropriately matched process parameters allows ring diamond wire cutting to meet the precision slicing requirements for this magnetic material.
