Прецизионная резка оптического стекла с помощью алмазной проволоки: 30.5 Данные испытаний стержня мм

Абстрактный: This application report covers a high-precision straight-slicing test on optical glass
supplied by a European customer. The workpiece was a rod of 30.5 mm diameter, cut into sections 15 mm long on an
ESO-GM gantry diamond wire loop cutting machine, with cutting oil as the cooling medium and a fully coated diamond
проволоки. Measured results across three sections: total thickness variation (TTV) 0.003-0.008 миллиметр, thickness tolerance
±0.141 mm against a 15.000 mm nominal, surface roughness Ra 0.58-1.06 мкм, и максимальное сколывание кромки
4.9-6.2 мкм. Matching machine structure, the oil cutting method, wire selection and process parameters to the
brittle behaviour of optical glass kept material removal stable and held section dimensional accuracy and cut-surface
quality inside a workable band.

Sample test for a European customer | Diamond wire loop cutting process

Overview of the Optical Glass Precision Slicing Test

This test was run on optical glass supplied by a European customer, with high-precision straight slicing as the
main requirement. Optical glass sits firmly in the hard, brittle family: hardness is fairly high, brittleness is
pronounced and fracture toughness is low. Once the diamond grains start abrading continuously, poor control of the
cutting load or of the temperature in the cutting zone concentrates stress inside the material, and that is where
сколы, micro-cracks, end-face damage and section dimensional deviation come from. The work therefore went at
machine structure, cutting method, wire selection and process parameters as one set, so the slicing stayed stable and
section dimensions and cut-surface quality could be held to the tolerances required for
Резка оптического стекла.

Because optical glass asks for dimensional accuracy, end-face quality and edge integrity at the same time, Энсолл
applied a diamond wire loop process matched to those characteristics. On the machine side the choice fell on a
dedicated gantry diamond wire loop cutting machine. Its rigidity and running stability give the workpiece a firm
clamping base and hold the wire on a steady path, which cuts down the effect of machine vibration and motion error on
the cutting trajectory and on section dimensions. On the consumable side, a diamond wire matched to optical glass
keeps the grains removing material at a steady rate, so a change in wire condition does not turn into a change in
section quality. For cooling and lubrication, cutting oil was used: it improves lubrication and heat dissipation at
the contact zone between wire and glass, lowers friction and heat build-up through the cut, and reduces what a local
temperature rise does to the cut face. On top of that, wire running speed and feed rate were set against the
properties of the material and the target section length, keeping the cutting load inside a suitable band and avoiding
the local overload and edge breakage that an aggressive feed produces. Станок, проволоки, oil cutting and parameters
matched as one set kept the process stable and brought section dimensional accuracy, равномерностью толщины,
cut-surface quality and edge integrity under control — a workable process basis for high-precision straight
slicing of optical glass. The same parameter logic applied to flat work is set out in our
BG38 glass sheet slicing test.

1. Объект испытания: Основная информация

• Материал: оптическое стекло
• Твёрдость: приблизительно MH 6 Кому 7
• Размеры заготовки: диаметр 30.5 миллиметр
• Размеры реза: 15 миллиметр (L) x 30.5 миллиметр (φ)

2. Выбор станка и проволоки

Тип станка: ESO-GM. Given the brittle behaviour of optical glass and the high-precision straight
резке, Ensoll выбрал алмазную проволочную пилу ESO-GM, the gantry machine built
for this class of work. Он обеспечивает стабильность работы и точность траектории во время реза, снижает влияние
machine vibration and load fluctuation on machining quality, ограничивает скалывание, micro-cracking and dimensional
deviation that uneven loading would otherwise produce, and so improves dimensional accuracy, cut-surface quality and
edge integrity in optical glass sections.

• Тип охлаждающей жидкости: cutting oil. Cutting oil is used as the cooling and lubricating medium. It improves
  lubrication and heat dissipation in the contact zone, lowers friction and heat build-up through the cut, and reduces
  the thermal and local stress variation the glass sees. That lowers the risk of chipping, micro-cracks and end-face
  damage, which helps dimensional stability, surface quality and edge integrity.
• Тип проволоки: полностью покрытая. A fully coated diamond wire raises the bond strength between grains and
  the steel core and keeps grain distribution even, so the wire removes material continuously and steadily through the
  cut. It reduces the effect of grain pull-out and wire wear on the cutting state, which limits dimensional variation
  and edge damage when slicing optical glass.

3. Метод резки и преимущества машины

Gantry cutting method. The gantry structure gives the machine high overall rigidity and running
stability, and the top-down vertical feed helps keep the Петля из алмазной проволоки on a stable
path, reducing the effect of load variation on kerf position and dimensional accuracy in optical glass sections. Тем
machine also carries a mist extraction system that clears the oil mist produced during cutting, keeping the work zone
clean and the cutting area in good condition for a stable run.

Интеллектуальная система управления натяжением. The system adjusts wire tension in real time according to the
machining state and supports both constant-tension and variable-tension modes, so the wire runs steadily through the
cut. Stable tension reduces trajectory drift and cuts the risk of wire breakage that tension variation brings, which
narrows the local load changes seen at the cut and helps control section dimensions and edge quality across the
batch.

Breakpoint resume. If the wire breaks or the machine stops abnormally, the system records the
current cutting position and the associated running state. After a wire change the cut resumes from that position,
which reduces the re-positioning error and repeat cutting that would otherwise affect cut position and quality, and it
keeps material loss down while the slicing run stays continuous.

High-rigidity one-piece cast iron frame. The one-piece cast iron frame raises overall stiffness and
vibration resistance, lowering the effect of structural vibration and deformation on the wire path. For a hard,
brittle material such as optical glass, that rigidity reduces load fluctuation during the cut and gives the dimensional
точность, cut-surface quality and edge integrity of precision slicing a reliable machine basis.

4. Parameter Settings and Cooling Method

The parameter set below was used for the whole run, and the sections reported in section 5 all came off it. Проволока
tension and wire speed are the two settings that carry most of the load control; the cutting load reading is what the
operator watches to keep the wire inside its working band.

Параметр	Значение
Диаметр проволоки (миллиметр)	0.35 x 1880
Скорость движения проволоки (мм/мин)	10
Ширина реза (миллиметр)	30.5
Cutting wire tension (N)	140
Скорость проволоки (М / сек)	24
Wire-bow time (s)	60
Нагрузка при резке (N·м)	20

5. Cutting Efficiency and Results

5.1 Данные теста TTV (миллиметр)

TTV (Изменение общей толщины) was measured with a nine-point grid, dual-probe thickness method on a vacuum-chuck
stage, applied to sections produced by diamond wire loop cutting. The sections measured 15 миллиметр (L) x 30.5 миллиметр (φ),
with a nominal thickness of 15 миллиметр. Before measurement the instrument was thermally stabilised and calibrated with a
standard thickness block to reduce zero drift and systematic error. После беспыловой очистки, each sample was centred
on the vacuum chuck and held by negative pressure, so that warping, tilt and position shift during measurement had
less effect on the thickness readings. Thickness data were then collected in sequence at the preset nine grid
positions, and the difference between the largest and the smallest reading across those points was taken as the TTV
of that sample, used to evaluate thickness uniformity and machining consistency. The procedure follows the method
explained in nine-point TTV measurement.

Образец	Nine-point thickness readings (миллиметр)	Tmax	Tmin	TTV
S01	15.056, 15.057, 15.058 / 15.059, 15.060, 15.061 / 15.062, 15.058, 15.057	15.062	15.056	0.006
S02	15.112, 15.113, 15.114 / 15.115, 15.113, 15.114 / 15.113, 15.114, 15.115	15.115	15.112	0.003
S03	15.135, 15.137, 15.138 / 15.140, 15.141, 15.142 / 15.143, 15.138, 15.139	15.143	15.135	0.008

Оценка: Looking at the nine-point readings for the three sections, S01 measured between 15.056
и 15.062 миллиметр, S02 between 15.112 и 15.115 mm and S03 between 15.135 и 15.143 миллиметр, giving TTV values of 0.006 миллиметр,
0.003 мм и 0.008 mm respectively. S02 held the tightest thickness uniformity and S03 showed the widest spread, but
every section stayed inside 0.008 миллиметр. Thickness variation across the measured areas is therefore small, which says the
wire ran steadily and the cutting state held through the run, and thickness consistency meets what high-precision
optical glass slicing asks for.

5.2 Данные по допуску толщины (миллиметр)

Thickness tolerance was measured by the same nine-point grid method, с 15.000 mm as the nominal thickness. Тем
deviation of each measured point from nominal was calculated, и максимальное положительное отклонение, maximum negative
deviation and overall thickness tolerance were collated, to assess dimensional accuracy and machining consistency of
the optical glass sections.

Образец	Средняя толщина (миллиметр)	Thickness deviation (миллиметр)
S01	15.059	+0.059
S02	15.114	+0.114
S03	15.141	+0.141
Максимальное положительное отклонение	+0.141	+0.141
Максимальное отрицательное отклонение	0	0
Допуск по толщине	±0.141	±0.141

Оценка: With 15.000 mm as nominal, the three sections averaged 15.059, 15.114 и 15.141 миллиметр,
corresponding to deviations of +0.059, +0.114 и +0.141 миллиметр. All three sat on the positive side, the maximum positive
deviation was +0.141 mm and no negative deviation was recorded, so the overall thickness tolerance is quoted as
±0.141 mm. Average thickness also rises steadily with sample number, which shows the batch carried a small
systematic bias towards the thick side. The bias is regular rather than random, so it is a compensation matter rather
than a process-capability one.

5.3 Данные по шероховатости поверхности Ra (мкм)

Шероховатость поверхности (Ra) was measured to ISO 4287 with a stylus profiler. Three representative positions were profiled
on the cut face of each section — centre, mid-left and mid-right — and Ra was calculated at each position
to assess the cut surface and machining quality.

Образец	Ra-1	Ra-2	Ra-3	Среднее значение Ra
S01	1.02	1.08	1.07	1.06
S02	0.55	0.61	0.58	0.58
S03	0.82	0.91	0.88	0.87

Оценка: Measured by the three-point method, average Ra came out at 1.06, 0.58 и 0.87 мкм
for S01, S02 and S03, so the whole set falls in the 0.58-1.06 μm range. The difference between measuring
positions on a single section is small, which means the cut face is fairly even and the process holds surface quality
under control. S02, which also held the best TTV, returned the lowest Ra — the two indicators moved together on
this run.

5.4 Edge Chipping Data (мкм)

Chipping was measured by optical imaging on a toolmaker’s microscope to quantify edge defects on the sections, which
измерены 15 миллиметр (L) x 30.5 миллиметр (φ) after cutting. Sample edges were cleaned before measurement, and the instrument
magnification and measuring scale were calibrated. The edge regions were then scanned under the microscope,
recognisable chips were located and measured, and the defect size at each point was recorded, giving an assessment of
edge quality and cutting performance.

Образец	Положение 1	Положение 2	Положение 3	Положение 4	Maximum chipping
S01	4.6	5.2	4.9	5.8	5.8
S02	3.8	4.5	4.1	4.9	4.9
S03	5.1	5.7	5.4	6.2	6.2

Оценка: Inspected by the four-point method, the largest chip measured 4.9-6.2 μm across
the three sections, with the individual measurement points sitting close together. Defect sizes are small and the
difference between samples is limited, which indicates a stable cutting state through the run and good edge integrity
on the sections.

6. Заключение

The optical glass in this run sliced well, and the result came mainly from matching a dedicated gantry machine, тем
oil cutting method and the process parameters as one set. Optical glass is a classic hard, brittle material: твёрдость
is fairly high, brittleness is pronounced and fracture toughness is low, and during diamond wire loop cutting the
continuous abrasion of the grains means that local cutting load and heat build-up easily concentrate stress, which
produces chipping, micro-cracks, an uneven cut face and section dimensional deviation. Aimed at the machining
behaviour of the material and the requirement for high-precision straight slicing, machine selection, cutting method
and parameters were all adjusted in a targeted way, holding section dimensional accuracy, thickness consistency and
cut-surface quality in check while the cutting process itself stayed stable.

First, machine selection. Given what optical glass slicing demands in motion stability, machine
rigidity and cutting accuracy, a dedicated gantry diamond wire loop cutting machine was selected. The gantry structure
provides good overall rigidity and running stability, which gives the workpiece firm clamping and the wire a reliable
mechanical basis for steady running, and reduces the effect of machine vibration, motion error and wire running
fluctuation on the cutting trajectory. Stable feed and motion control also narrow the cutting-load variation, so wire
and glass stay in a comparatively steady relative motion, which lowers the risk of dimensional deviation and local
chipping and gives high-precision slicing a stable machine basis.

Во-вторых, cutting method. Optical glass is markedly brittle and sensitive to thermal effects during
режущий, so oil cutting was used, with cutting oil as the cooling and lubricating medium. Cutting oil improves
lubrication and heat dissipation in the contact zone between wire and glass, lowering friction and heat build-up and
reducing the effect of local temperature rise and thermal stress on the material. Steady cooling and lubrication also
help hold the cutting zone in a consistent state and reduce the cutting fluctuation that friction or concentrated heat
would cause, so chipping, micro-cracks and end-face damage become less likely and the cut surface and edge integrity
improve.

Third, параметры процесса. Against the material properties and the target section size, проволоки
running speed and feed rate were matched accordingly. Parameters were set to keep the wire running stably and material
removal even, avoiding a feed rate so high that the cutting load climbs, and avoiding a combination that produces
локальный нагрев, stress concentration and brittle fracture. The targeted adjustment kept material removal comparatively
steady and, while still meeting machining efficiency, reduced impact and load fluctuation through the cut, which
improved thickness consistency, cut-surface quality and edge integrity.

В целом, the results for section dimensional accuracy, thickness tolerance, шероховатость поверхности (Ra) и
качество кромки разреза показывают, что, with a dedicated gantry cutting machine, oil cutting and suitable parameters working
together, diamond wire loop cutting meets the requirements of high-precision straight slicing for optical glass. Тем
samples performed steadily in dimensional accuracy, равномерностью толщины, cut-surface quality and edge integrity,
which indicates that matching machine structure, cooling and lubrication method and process parameters to the
properties of the material improves the removal state and process stability, and offers a process reference for
high-precision straight slicing of optical glass.

Часто задаваемые вопросы

Can a diamond wire loop slice a 30.5 mm optical glass rod into 15 mm sections?

Да. In this test a rod of 30.5 mm diameter was cut into sections 15 mm long on an ESO-GM gantry machine, с
cutting oil and a fully coated 0.35 x 1880 mm wire running at 10 mm/min travel, 140 N tension and 24 m/s wire speed.
Measured TTV was 0.003-0.008 миллиметр, thickness tolerance ±0.141 mm, среднее Ra 0.58-1.06 μm and maximum
сколы 4.9-6.2 мкм.

What TTV can be held when slicing optical glass with a diamond wire loop?

In this run TTV was 0.006 миллиметр, 0.003 мм и 0.008 mm across three sections, measured by the nine-point grid method
on a vacuum chuck against a 15 номинальной толщиной мм. All three sat inside 0.008 миллиметр, which is the sort of uniformity a
precision slicing process needs before any lapping or polishing step.

Why use cutting oil instead of a water-based coolant for optical glass?

Cutting oil lubricates and cools the contact zone between wire and glass. Here it improved heat dissipation in the
cutting zone and lowered friction and heat build-up, which cut the thermal and local stress variation the glass sees
and lowered the risk of chipping, micro-cracks and end-face damage. The machine carries a mist extraction system to
clear the oil mist produced during the cut.

How much edge chipping should be expected on sliced optical glass?

In this test maximum chipping came to 4.9-6.2 μm measured by optical microscopy, with four positions checked
per section. Individual measurements were tightly grouped, so the chip size is small and consistent rather than
occasional deep damage — an edge condition that normally cleans up in a light finishing pass.

Why did all three optical glass sections come out thicker than nominal?

Against a 15.000 mm nominal, the sections averaged 15.059, 15.114 и 15.141 миллиметр, so every one ran on the plus side
около 0.059 Кому 0.141 миллиметр. Because the deviation moves steadily with sample number it is a systematic offset, not random
scatter, and the practical fix is dimensional compensation on the next run rather than a change to the cutting
parameters.

Технический контент проверен инженерной командой Ensoll – производитель алмазной проволочной петли с 10+ многолетним производственным опытом.