세라믹 절단용 환형 다이아몬드 와이어 톱

현재, 단단하고 부서지기 쉬운 재료의 톱질 및 절단 공정은 낮은 가공 효율성과 같은 문제로 어려움을 겪고 있습니다, 낮은 재료 수율, 열악한 표면 품질 및 무결성, 높은 공구 비용, 그리고 환경 오염. When using circular saws to cut materials like stone and 도예, 톱날은 강성을 보장하기 위해 일정한 두께를 가져야 합니다. 그 결과 넓은 커프가 생성됩니다, 낮은 재료 수율, 그리고 심각한 오염. 또한, 원형 톱은 형상 표면 가공을 수행할 수 없습니다., leading to inferior surface quality when cutting ceramic materials. In the semiconductor industry, the use of free abrasive wire cutting methods to process silicon crystals results in significant surface and environmental contamination by diamond abrasive slurry, thereby increasing the costs associated with subsequent processing and waste treatment.

다이아몬드 와이어 톱 is a hard and brittle material cutting method that has experienced rapid development in the past decade, primarily involving the use of free abrasive and bonded abrasive types. Based on the wire saw’s motion and machine structure, it can also be classified as reciprocating and unidirectional wire saws. 현재, reciprocating multi-wire saws using free abrasives dominate in the semiconductor and optoelectronic industries. To address issues such as low cutting speeds and abrasive slurry contamination, the diamond unidirectional wire saw utilizing bonded abrasives has been proposed. This type of wire saw features a simple structure, enables high-speed wire movement, and allows for shaping operations, thus holding significant practical importance in advancing equipment for processing hard and brittle materials. The bonded abrasive diamond annular wire saw offers the following advantages:

(1) 좁은 절단면, high material yield. By using high-strength steel wire as the base material, various wire saws with diameters below 1mm can be produced. Companies like Sumitomo Electric Industries and Lid in Japan have manufactured wire saws with average diameters ranging from 0.175 to 0.180mm using steel wires with diameters of 0.130 and 0.155mm as the base material, achieving an actual kerf loss of 0.19mm in sodium glass cutting experiments.

(2) Fast cutting speed, 고효율. The bonded abrasive annular diamond wire saw features unidirectional movement of the wire saw during the cutting process, with the abrasive grains fixed on the wire saw, eliminating the difficulty of abrasive entry into long and deep kerfs. Compared to reciprocating structures and wire saws using free abrasives, it is easier to achieve higher cutting speeds, resulting in high processing efficiency.

(3) Smooth cutting process, good slice surface quality. During the cutting process with a diamond wire saw, the cutting force is small and gentle, without the unique grooves generated on the workpiece surface due to reciprocating wire saw movement.

(4) Minimal environmental pollution. Bonded abrasive diamond wire saws typically use water as the standard coolant, and dry cutting methods can even be employed at lower wire speeds. This results in low or no need for wastewater treatment due to the use of bonded abrasives.

결론, in today’s increasingly widespread applications in non-conductive materials, semiconductor materials, 및 복합 재료, the bonded abrasive diamond wire saw demonstrates unique advantages in cutting hard and brittle materials. 그렇지만, current research and applications are insufficient, particularly in areas such as wire saw manufacturing technology, cutting processes and mechanisms, diamond wire saw failure modes and mechanisms, and wire saw posture and motion control technologies in precision shaping cutting. There are many significant gaps that warrant further exploration. This study aims to explore electroplated diamond wire saw cutting technology, deeply understand its cutting mechanisms, and promote the precise and efficient processing of hard and brittle materials, which holds important significance.
Annular saws suit certain shapes; for flat precision work the reference is precision cutting of alumina.

자주 묻는 질문

What is an annular diamond wire saw?

It is a bonded-abrasive wire saw in which diamond grains are fixed on a wire loop that moves unidirectionally at high speed. The simple structure allows high wire speeds and shaped cutting of hard, brittle materials such as ceramics — an alternative to reciprocating free-abrasive wire saws.

What advantages does a bonded-abrasive wire saw have over free-abrasive sawing?

Because the diamond grains are fixed on the wire, there is no abrasive slurry that must enter long, deep kerfs, so higher cutting speeds are achievable. It also produces a narrow kerf with high material yield, a smooth cut surface without reciprocating grooves, and far less contamination.

How narrow is the kerf of a diamond wire saw?

Manufacturers such as Sumitomo Electric Industries and Lid in Japan have produced wire saws averaging 0.175-0.180 mm in diameter on steel cores of 0.130-0.155 밀리미터, achieving an actual kerf loss of about 0.19 mm in sodium glass cutting experiments.

Is diamond wire sawing environmentally friendly?

Relatively yes. Bonded-abrasive diamond wire saws typically use plain water as coolant, and dry cutting is even possible at lower wire speeds. With no free-abrasive slurry, there is little or no wastewater treatment required — a major contrast with slurry-based silicon wafering.

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