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WO2014063910A1 - Fil à scier abrasif fixe plat - Google Patents

Fil à scier abrasif fixe plat Download PDF

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Publication number
WO2014063910A1
WO2014063910A1 PCT/EP2013/070710 EP2013070710W WO2014063910A1 WO 2014063910 A1 WO2014063910 A1 WO 2014063910A1 EP 2013070710 W EP2013070710 W EP 2013070710W WO 2014063910 A1 WO2014063910 A1 WO 2014063910A1
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WO
WIPO (PCT)
Prior art keywords
wire
metal
fixed abrasive
sawing
matrix material
Prior art date
Application number
PCT/EP2013/070710
Other languages
English (en)
Inventor
Roland Groenen
Jan Vaneecke
Tom Baekelandt
Original Assignee
Nv Bekaert Sa
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nv Bekaert Sa filed Critical Nv Bekaert Sa
Publication of WO2014063910A1 publication Critical patent/WO2014063910A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D61/00—Tools for sawing machines or sawing devices; Clamping devices for these tools
    • B23D61/18—Sawing tools of special type, e.g. wire saw strands, saw blades or saw wire equipped with diamonds or other abrasive particles in selected individual positions
    • B23D61/185—Saw wires; Saw cables; Twisted saw strips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D65/00—Making tools for sawing machines or sawing devices for use in cutting any kind of material

Definitions

  • the invention relates to fixed abrasive sawing wire that can be used to cut hard and brittle materials such as natural or artificial stone, ceramics, crystalline materials such as mono- or polycrystalline silicon, gallium arsenide, or quartz, amorphous materials such as glass or even magnets.
  • the invention further relates to a method to produce such a wire. Also a method and apparatus to use the inventive wire is included.
  • a saw is equipped with abrasive elements such as protruding teeth or abrasive particles arranged on a carrier.
  • the abrasive elements abrade the material away and evacuate the debris formed.
  • the carrier can for example be a circular or rectangular blade with the abrasive elements arranged along the rim.
  • the carrier can be an elongated element that is closed into a loop such as a chain saw, a band saw or a closed loop sawing wire.
  • the carrier is generally a steel wire of high tensile strength on which abrasive particles (such as diamond particles) are attached by means of a metal braze, a resin bond, or by means of indentation in a soft metal layer or incorporation in an electrolytically applied binder layer.
  • abrasive particles such as diamond particles
  • Such wires allow for very fine kerfs but at a limited cutting stretch of below 400 mm.
  • Thicker fixed abrasive sawing wires (up to about 0.25 mm diameter) exist for cutting large ingots of polycrystalline silicon into square blocks as there the stretch is longer (typically 1 .0 to 1 .5 meter).
  • Such saws are popular and are known as 'band saws' or 'blade saws'.
  • a band or blade saw the abrasive elements are always attached to one or both of the thin rims of a ribbon shaped carrier.
  • a blade saw is of finite length and works in a reciprocal way.
  • the band saw is made in a closed loop and guided over flat wheels that tension the saw while driving it.
  • the axes of the wheels are parallel to the cutting direction.
  • the increased stiffness in the cutting direction helps to push the saw blade through the work piece.
  • the thin blade allows for maximum grip on the wheels.
  • guiding wheels sometimes are needed to push and/or guide the band saw through the work piece.
  • Band saws or blade saws generally have the abrasive elements on the thin rim of the blade only (the rim spanned by the thickness and length dimension). Apart from teethed saws (that fall outside the scope of this application) the following prior art band saws or blade saws based on abrasive particles have been described:
  • JP 2010 167509 discloses a fixed abrasive grain saw wire having a pair of parallel flat parts wherein abrasive grains are fixedly attached only to the curved surface connecting both flat parts;
  • GB 1216428 describes a method to provide abrasive particles on the edge of a band saw.
  • Blade saws additionally have the disadvantages that they have to be used in reciprocating way whereby the continued acceleration and deceleration takes a lot of energy. Also due the reversal of the direction sawing time is lost leading to a lower cutting speed.
  • the main goal of the invention is to provide a fixed abrasive sawing wire that does away the problems associated with blade saws or band saws. More specifally a fixed abrasive sawing wire is provided that better keeps track even when cutting anisotropic materials and allows for multiple parallel and straight cuts. Such a fixed abrasive sawing wire could be used for cropping of silicon ingots, sawing of stone, particularly stone veneer cutting, and even on hand held or portable wire saws. A further goal is to provide a method to produce this kind of wire. The use of the wire itself is also an object of the invention as well as a wire saw to use the wire on.
  • 'wire saw' is meant an apparatus to saw work pieces while the wording 'sawing wire' or 'saw wire' is used for the utensil that is driven in a wire saw and that performs the actual sawing.
  • the fixed abrasive sawing wire comprises a metal wire and abrasive
  • the metal wire has a cross section in the plane perpendicular to the axis of the wire that shows an 'oblong' shape.
  • an 'oblong' cross section is a cross section having a thickness and a width, the thickness being smaller than the width.
  • any two dimensional cross section can be delimited between two parallel tangent lines a certain distance from one another which is called the Feret distance. Depending on the angle by which the tangent parallel lines are oriented to the shape this distance will vary.
  • the pairs define the smallest rectangle that completely covers the cross section.
  • the smaller of the two Feret distances will be called the 'thickness', and its associated direction is the 'thickness direction'.
  • the larger Feret distance will be called the 'width' and its associated direction is the 'width direction'.
  • With 'width side' is meant that side visible when viewed in the thickness direction, and with 'thickness side' is meant that side visible when viewed in the width direction.
  • width sides there are two width sides and two thickness sides. As the width is associated with the larger Feret distance and the thickness with the smaller distance of the pair of couples of parallel tangent lines, the width will be larger than the thickness.
  • Cross sections in the form of an ellipse, a rectangle, an oval, a diamond, a scalene triangle, an isosceles triangle, an egg-shape, a kidney shape are oblong.
  • the inventors put the abrasive particles on the width side and not on the thickness side of the metal wire.
  • the abrasive particles can be present on both width sides. When present on both sides, both sides can be used for cutting. This can be advantageous when e.g. the sawing wire can be spooled from a pay-off spool to a take-up spool. When re-using the wire on the take-up spool the other side of the wire can be used.
  • the wire can be used in a reel-to-reel mode but also in a closed loop mode.
  • the width 'W of the fixed abrasive sawing wire preferably covers the
  • the sawing wire covers the gap between the relatively thick round sawing wires (of about 0.25 mm) and thin band saws (with kerf losses of more than 4 mm) More preferably a width range of between 1 mm to about 4 mm or even from 1 to 3 mm is envisaged.
  • the ratio of the width 'W' to the thickness 't' of the oblong cross section must be chosen in function of the application. For a given width 'W it is advantageous that at least the thickness 't' is less than the width 'W. The smaller 't' becomes, the more flexible the fixed abrasive wire saw will be in the thickness direction. Indeed, the 'stiffness' of a flat wire is equal to ExWxt 3 /12 wherein ⁇ ' is the modulus of the steel.
  • the ratio of 'W/t' must therefore preferably be at least larger (lower limits) than 1 .5, preferably even larger than 2, or 3, or 5 or even 8.
  • the material the wire is made of is a metal.
  • Particularly preferred wires are high strength steel wires, plain carbon steel wire, stainless steel wire such as AISI304 or AISI316, a chrome vanadium steel wire, a chrome
  • molybdenum steel wire a chrome molybdenum vanadium steel wire or a chrome molybdenum nickel steel wire. More preferred steel compositions are:
  • the tensile strength of the wire must be as high as possible in order to be able to reduce its thickness 't' while maintaining the necessary strength.
  • tensile strength in excess of 900 N/mm 2 are easily obtainable, while tensile strengths larger than 1200 N/ mm 2 and even larger than 1400 N/mm 2 are available.
  • the matrix material that holds the abrasive particles is by preference a metal matrix material.
  • a metal matrix material has the advantage that the wear of the matrix can be adapted to the wear of the abrasive particles.
  • a first method is to use electrolytic deposition of a metal layer from an
  • the abrasive particles are concomitantly introduced and bonded into that layer.
  • Typical metals that are used to this end are nickel, nickel phosphorous, nickel tungsten, nickel manganese, nickel cobalt, cobalt or cobalt phosphorous.
  • the metal wire may be coated with a nickel or a copper or an iron layer in order to improve adhesion of the metal matrix to the wire.
  • a second method is the method of brazing.
  • mixture of abrasive particles and a low temperature melting solder is, possibly held together in organic binder, applied on the wire and
  • solder or braze melts and holds the abrasive particles to the wire.
  • the powder can be made to melt by means of a laser.
  • Typical solders comprise tin and/or zinc possibly with a further alloying metal such as bismuth, nickel, copper iron, lead, antimony, indium and/or silver.
  • the wire is coated with copper, or a copper-zinc alloy to improve wetting of the solder to the wire.
  • a third and preferred method uses cladding, such as laser cladding,
  • thermal spray or plasma spraying Most preferred is the laser cladding technique.
  • a metal powder and abrasive particles are gas propelled through a nozzle onto a spot on the metal wire.
  • the wire spot is preheated by means of a high-power laser and the fed metal powder melts while the abrasive particles are impelled into it. After cooling a very good bond remains with the metal wire. The bond can even be further improved by pre-coating the wire with a bronze (copper tin alloy).
  • An alternative way to feed the metal matrix is by means of a wire feed instead of a powder feed.
  • alloys of metal matrix materials that are suitable for use with a laser cladding system. Given the constraints imposed by the abrasive particles alloys with melting temperatures between 400°C and 900°C are more preferred. These alloys comprise silver, copper, nickel or cobalt as main alloy element. Additionally, melting temperature reducing elements such as tin, zinc, or indium can be added. In the case of nickel non-metals like phosphorous, silicon or boron can be used to reduce the melting temperature.
  • brazes copper and zinc as main elements
  • bronzes copper and tin as main elements
  • Even more preferred alloys are silver based such Ag-Cu, Ag-Cu-Zn, or Ag-Cu-ln.
  • the matrix shows sufficient ductility. Ductility is expressed, amongst others, in the elongation the metal matrix can withstand without breaking. As the wire is flexible at least in the direction of its thickness, the abrasive matrix must be able to follow the bending of the wire. Additionally, these alloys give a good balance between abrasive use and matrix wear. If the matrix wears too fast, abrasive particles will be dislodged while not being used to the full leading to premature tool wear. Conversely, if the matrix is too wear resistant, abrasive particles will not protrude sufficient for cutting resulting in too low sawing speeds.
  • alloys that contain an additional active metal such as chromium, titanium, vanadium, tungsten, zirconium, niobium,
  • molybdenum, tantalum, hafnium or combinations thereof More preferred are chromium, zirconium, vanadium or titanium of which the latter is the most preferred as it has the lowest melting point. These metals are active in two ways:
  • bronzes contain between 5 and 30 wt%Sn, between 0.5 and 15 wt%Ti, the remainder being copper. Good results were obtained with bronzes having between 10 and 20 wt%Sn and between 2 and 10 wt%Ti, the remainder being copper.
  • An example is an alloy containing 14 %Sn, 8 %Ti the remainder being copper, all expressed in weight percentage of the total.
  • a particular example of a silver copper based alloy is Cu 27.25 wt%, Ag 59 wt%, In 12.5 wt% and, 1 .25 wt % of Ti.
  • Such an alloy has a good combination of strength and ductility (tensile strength 455 MPa, Young's modulus 76 GPa, elongation 21 %).
  • Possible abrasive particles are diamond, cubic boron nitride, silicon carbide, aluminium oxide, silicon nitride, tungsten carbide, titanium carbide or mixtures thereof. Carbon containing particles - diamond, silicon carbide, tungsten carbide, titanium carbide or mixtures thereof - are more preferred as they are easily wettable by all active metals mentioned.
  • Nitrides i.e. cubic boron nitride, silicon nitride
  • Nitrides are best wetted with titanium.
  • diamond i.e. almost pure carbon
  • the former being more preferred for its lower cost.
  • mixtures of abrasive particles such as e.g. diamond with tungsten powder can be envisaged.
  • the active metal can also be provided on the surface of the abrasives for example in the case of diamond.
  • Diamond particles coated with tungsten, chromium or titanium are available.
  • the size and type of the abrasive particles are determined by the type of material to be sawn, but also by dimensions of the metal wire.
  • Particles for stone cutting are generally large grit (US mesh sizes 30/40 to 50/60, mesh sizes according to US Standard ASTM E 1 1 , the higher the numbers, the smaller the particles) while for silicon cutting micro grits can be
  • the abrasive particles must have a minimum size to be able to fluidize them in a gas stream for laser cladding.
  • the inventors therefore limit the size of the particles to above 30 ⁇ for example with a grit size larger than US mesh 325/400 (mean size larger than 46 ⁇ ).
  • the amount of abrasive particles is also depending on the material to be sawn but for most purposes about 100 to 2000 mg/cm 3 of abrasive material taken relative to the total volume of the layer should suffice. More preferred is 100 to 500 mg/cm 3 . In the case of diamond this is expressed in carat as 0.5 to 10 ct/cm 3 (1 carat, 'ct' is 200 mg) or even 0.5 to 2.5 ct/cm 3 .
  • a fixed abrasive sawing wire with an abrasive layer obtained by laser cladding shows a metallurgical structure quite different from the layers as obtained by electroplating or brazing that form in a quasi static thermal equilibrium.
  • the latter matrices show a granular or grain structure in a metallographic cross section.
  • a metal matrix material deposited with laser cladding the components of the metal alloys in the molten metal pool do not get the chance to reach a thermal equilibrium. Due to the presence of a spatial high temperature gradient, the growing solid phase will seek the most effective way to eject superfluous solute components into the liquid again in order to meet the preferred intermetallic phase of the solid.
  • laser cladding a series of microstructures can be obtained such as cellular, dentritic or columnar growth. See "Laser Cladding" by E.
  • This temperature gradient is dependent on the relative speeds between the clad track and the substrate: higher relative speeds lead to finer dendritic structures.
  • the fineness of the microstructure is also considered to contribute to the hardness and resistance to wear of laser clad layers: the finer the structure the higher the wear resistance.
  • a metallurgical bond layer is provided between the metal wire and the metal matrix material.
  • Such a metallurgical bond layer can for example be electrolytically applied to the metal wire, but by preference it is applied by laser cladding.
  • the composition of the metallurgical bond layer is similar to that of the metal matrix material with the exception that the presence of an active metal (such as chromium, titanium, vanadium, tungsten, zirconium, niobium, molybdenum, tantalum, hafnium or combinations thereof) is not desired. It is known that the presence of such active metals deteriorates the bond of the matrix material to the metal wire (EP 1027476). In general this metallurgical bond layer can be smaller than 0.2 mm, or even less than 0.1 mm.
  • an active metal such as chromium, titanium, vanadium, tungsten, zirconium, niobium, molybdenum, tantalum, hafnium or combinations thereof.
  • the abrasive particles in the metal matrix material will - at least locally - add to the thickness of the sawing wire.
  • the maximum thickness of the metal matrix material with abrasive particles will be indicated with 't mmm ' in what follows.
  • the total thickness 't mmm +t' preferably remains smaller than the width 'W of the sawing wire.
  • the thickness of the metal matrix material with abrasive particles 't mmm ' is about the thickness 't'.
  • a lower thickness such as 't mmm ' being smaller than 0.75, 0.50, or 0.25 times 't' will induce less stress on the metal matrix material during bending of the wire.
  • the thickness 't mmm ' must at least be larger than the mean abrasive particle diameter in order to have at least one layer of abrasive. By preference it is larger than 2 or 5 or 10 times the mean particle size of the abrasive particles. The thicker the matrix material with abrasives is, the more material for abrasion is available, the longer the sawing wire can be used.
  • the metal matrix and abrasive material are present over one or both of the complete width sides of the sawing wire.
  • the abrasive particles held in the matrix material are present in discrete sections along the length of the width side of the wire. This to provide space in between the sections to remove debris from the cut. In between the sections the metal matrix material can still be present or alternatively both abrasive particles and metal matrix material are absent in between the sections.
  • the former embodiment has the advantage that the metal matrix is not interrupted leading to a more constant stiffness along the length of the wire.
  • the latter embodiment has the advantage that more space is available between the sections to remove swarf from the cut.
  • the discrete section can be arranged on the width side of the sawing wire in different forms: the sections can have the shape of a rectangle or a parallelogram when arranged either perpendicular or obliquely to the axis of the wire. The sections can also be alternatively present on the upper and lower side of the sawing wire.
  • the sections are at least 3 or 5 or 10 times or more the
  • the discrete sections should not be separated too much from one another as otherwise the speed of sawing is adversely affected. 5 or 10 or 50 times the width 'W is considered a maximum.
  • the length of the discrete sections is at least the width of the sawing wire. The number of sections per unit length will depend on the type of material sawn. Relatively soft materials - such as marble or travertine - will need lower sections per meter (say below 10 to 35 sections per meter) as the stone will otherwise start to load the abrasive particles. Hard materials - such as granite - will need 40 to 50 sections per meter.
  • the total length of the sections per meter is equal to the sum of the length of the sections per meter and is called 'coverage degree'.
  • the coverage degree - when discrete sections are used - is between 20 to 80 %. More preferred is between 30 and 50%.
  • An alternative embodiment is one wherein the abrasive particles in the matrix material are present in a continuous path on one or both width sides of the sawing wire.
  • This continuous path can cover the complete width over the complete length of the wire.
  • the continuous path can take the form a zig-zag path meandering from one edge to the other edge of the wire.
  • an important embodiment is that wherein the fixed abrasive sawing wire is closed on itself i.e. forms a loop.
  • One possibility is to close the loop by welding the ends of the metal wire to one another, prior to application of the abrasive particles in the matrix material. This allows the weld to be made in the best possible conditions.
  • the loop can be closed on the finished fixed abrasive sawing wire. The advantage there is that the loop can be closed on site i.e. on the pulleys whereon the wire will run.
  • An alternative to making a weld is to use a feather edge connection.
  • the loop can be made in the form of a Mobius band.
  • one of the ends of the sawing wire is axially twisted 180° prior to welding.
  • the presence of the half-turn will induce a torsion moment to the wire which will make it rotate, at least when the overall cross section of the sawing wire is more or less circular so that it allows rotation.
  • the wire will also turn when the wire is twisted over any integer multiple of 180° and subsequently welded.
  • a limit is quickly reached as this is detrimental to the fatigue life of the wire.
  • the method comprises the steps of:
  • the wire is guided over a wheel with the inner width side of the wire contacting the wheel.
  • the inner width side of the wire is meant that side radially inward towards the wheel's axis.
  • the wire is held in close, non-sliding contact with the wheel by applying sufficient tension while being rolled over the wheel.
  • Abrasive particles in a metal matrix material are applied onto the outer width side of the wire.
  • the Outer width side' of the wire is that side that is oriented radially outward relative to the axis of the wheel.
  • a supply of metal matrix material is molten by a laser beam on said wire.
  • a supply of abrasive particles is thrown into the pool of molten metal matrix material.
  • the wheel has a diameter smaller than about 1000 times the thickness 't' of said metal wire but larger than 100 times the thickness 't' of the metal wire.
  • the supply of abrasive particles can be intermittent so that sections
  • abrasive particles and metal matrix material alternate with sections of metal matrix material only.
  • the abrasive material and metal matrix material can be supplied synchronously or 'in sync'. In that case sections with abrasive particles and metal matrix material alternate with sections that are free of both.
  • a high intensity laser capable of delivering beams of at least 500 W continuous or pulsed power, by preference emitting in the infra-red region of the spectrum.
  • Particularly suited are Nd:YAG (neodymium doped yttrium-aluminium garnet) lasers pumped by flash lamps or solid state lasers or CO 2 gas lasers.
  • the laser-light is guided through suitable wave guides and optics to have a focal point that is adjustably close to the metal wire;
  • the powder can e.g. be supplied in a carrier gas, preferably a non-oxidising gas or inert gas such as argon;
  • a supply of abrasive particles are by preference carried by a stream of carrier gas.
  • the type of gas for carrying the abrasive particles and for carrying the metal matrix material is the same.
  • the supply of abrasive particles can simply be done by strewing.
  • each one of the supplies of metal matrix powder, of the abrasive particles or of the heat input by means of the laser can be modulated independently.
  • the supply of metal matrix powder and abrasive particles can be combined although this is not a necessity.
  • the stream of carrier gas is directed by means of a gun such as described in US 6,31 6,744 wherein the gas flow is coaxial to the laser beam and converges towards the focal point through a conical annular nozzle.
  • a laser gun is also cooled by water in order to prevent heating of the nozzle.
  • the metal matrix material can be fed through the laser gun, while the abrasive is delivered through a separate gas flow or simply by strewing.
  • the metal matrix material can be delivered through a nozzle separate from the laser gun while the abrasive particles are fed through the laser gun.
  • both abrasive particles and metal matrix material can be supplied through the laser gun. Preferred is that abrasive particle supply and metal matrix material supply are separate as they do have quite distinct powder - and hence flow - properties.
  • the degree of compression induced by straightening the wire at the outer surface of the wire - i.e. at the interface between metal matrix material and metal wire - is from 0.2 % (for a wheel of 10OOxt) to 5 % (for a wheel of 40xt).
  • the wire In order to prevent the deterioration of the strength properties of the metal wire, the wire must be cooled. This can be done by cooling the wheel on which the wire is running. In case the cross section of the wire is not rectangular, a groove is made in the wheel that matches the shape of the inner width side of the metal wire. Possibly a thermoconductive fluid can be introduced between the wire and the wheel to improve the thermal contact even further.
  • the wheel can be equipped with double flanges where in between the metal wire is guided.
  • the wheel is made of a metal that allows for a good heat conduction but also that reflects the laser light efficiently. This is to be prevent that the wheel would become easily coated with metal matrix material.
  • a method to saw a hard and brittle work piece is presented using the above described fixed abrasive sawing wire.
  • the sawing wire is used with a width side comprising the abrasive particles facing the work piece. This in contrast with a band saw that is sawing with the thickness side facing the work piece.
  • a wire saw is disclosed for use with the
  • the wire saw comprises pulleys that guide the sawing wire to the work piece. At least one of the pulleys is driven to transfer motive force to the wire.
  • the wire saw presents the sawing wire to the work piece with the width side comprising abrasive particles facing towards the work piece.
  • the wire saw fills the gap of sawing stretches between 400 mm to 2000 mm.
  • a loop of sawing wire is used tensioned between at least two pulleys of which at least one is driven.
  • a large length of fixed abrasive sawing wire is unreeled from a pay-off spool guided through the wire saw, saws the work piece and is wound on a take-up spool after use.
  • Figures 1 a and 1 b show a conventional band saw.
  • Figures 2a to 2d show possibly different cross sections of the fixed
  • Figure 3 is an illustration of the dendritic microstructure obtained in a
  • Figure 4a to 4d show different ways in which the abrasive particles can be deposited on the inventive fixed abrasive sawing wire.
  • Figure 5 shows an exemplary way to produce the fixed abrasive sawing wire according the invention.
  • Figure 6 shows an embodiment of the inventive fixed abrasive sawing
  • Figure 7a and 7b show two possible ways how the fixed invention abrasive sawing wire can be welded.
  • Figure 8a and 8b shows a saw machine using the invention fixed abrasive sawing wire must be used.
  • a closed loop band saw 102 runs over two pulleys 104, 104' driven by a motor.
  • the band saw is provided with a rim 106 of abrasive particles on a closed metal band 1 10.
  • Possibly guiding pulleys 103 are provided to guide the band saw 102 when sawing through the work piece 108.
  • the band saw saws in the direction V i.e. in the plane of the band saw.
  • Figure 2a to 2d shows different embodiments of the invention in cross
  • Each of the embodiments shows a metal wire having an oblong cross section: 210a rectangular, 210b oval, 210c kidney shape, 21 Od triangular.
  • the cross section has a width 'W and a thickness T.
  • abrasive particles 214 are present that are held in a metal matrix 214 in each of the embodiments.
  • the embodiment of Figure 2d is made by means of electrolytic co- deposition of abrasive particles and a matrix metal.
  • the abrasive particles are diamonds that are nickel coated (prior to co- deposition) and the matrix metal is nickel. The pre-coating helps to deposited the diamond particles.
  • the embodiment of Figure 2b shows a roughened interface 218 while the abrasive layer is deposited by means of brazing.
  • the brazing is preferably done with a low melting point solder such as a tin silver (4 wt% of silver) or other compounds having a low melting point.
  • the solder in the form of a metal powder and organic binder paste is applied together with the abrasive particles to the width side of the metal wire. By first baking out the binder and subsequently heating the wire above the solder melting point the solder melts thereby fixing the abrasive particles.
  • a binding layer 216 forms that is an alloy of the material of the metal wire and the metal matrix.
  • the nominal composition is between 0.47 to 0.55 %wt carbon, max. 0.4 %wt silicon, between 0.7 and 1 .1 %wt Mn, maximum 0.025 %wt phosphorous, maximum 0.025 %wt sulphur, between 0.9 and 1 .2 %wt chromium, between 0.1 and 0.25 %wt vanadium and the remainder being iron.
  • the wire has a rectangular cross section of 0.3 mm in thickness and a width of 2 mm and a tensile strength of 1 100 N/mm 2 and is provided on a spool.
  • the wire 510 ( Figure 5) is continuously unwound and guided over a brass wheel 534 of diameter 'D' 10 cm (i.e. 333 times the thickness).
  • the brass wheel is cooled by means of water.
  • the brass wheel is polished in order to reflect the laser light as much as possible.
  • the wire is held tight on the wheel with a force of about 200 N.
  • the brass wheel 534 is provided with flanges 535 to ensure that not too much material is spilled sideways.
  • a laser gun 502 is provided with a central laser waveguide 530 with a coaxial gas powder feed 504.
  • metal matrix alloy powder 514 an alloy compositon CuSnTi 78/13/9 (wt%), gas atomised with a median diameter of 50 ⁇ is used.
  • gas atomised with a median diameter of 50 ⁇ is used.
  • abrasive particles saw grit diamond of mesh 40/50 (315 to 400 ⁇ particle size) of the MBS series of Diamond Innovations is used.
  • the concentration of the diamond is 7% in volume related to the metal matrix.
  • the reactive titanium in the metal matrix powder ensures good bonding of the diamond to the metal matrix.
  • Argon is used as a protective gas.
  • coated discrete sections can be any suitable material.
  • the fixed abrasive sawing wire can be made endless by welding two ends of the wire together as shown in Figure 7.
  • the ends are welded flush at weld 720 resulting in loop 710.
  • a half turn has been added to the ends prior to welding at 740 resulting in Mobius band 730.
  • this wire should have cutting sections at both width sides as a Mobius band is one sided.
  • the loop can be welded prior to laser cladding the cutting sections on the metal wire. In that case the loop is first formed and then held tight between wheels.
  • the fixed abrasive sawing wire can be used as depicted in Figures 8a and 8b. Opposite to the band saw, the wire is used now in the width direction and the wider part 814 of the wire 810 now cuts its way through the work piece 808 in direction V. Contrary to a band saw, it is possible to mount wires side by side and to use this kind of wire for slabbing. In that case the driving pulleys 804 of the machine is equipped with parallel grooves. In an alternative embodiment of the saw machine, the wire is dereeled for a payoff spool onto a take up spool. In case sufficient length can be
  • the inventive fixed abrasive sawing wire fills the gap in sawing wires
  • the associated machine provides an intermediate between a large kerf sawing cord slicer and a small kerf multiwire saw.

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  • Polishing Bodies And Polishing Tools (AREA)

Abstract

La présente invention concerne un fil à scier abrasif fixe, les particules abrasives étant maintenues dans une matrice métallique fixée à un fil métallique. Le fil métallique présente une section transversale oblongue et la particularité du fil réside en ce que les particules abrasives sont présentes sur le côté de la largeur du fil métallique. La présente invention concerne également des procédés permettant de produire ce fil de manière avantageuse. Le fil à scier abrasif fixe peut être utilisé sous forme de boucle simple dans une machine à scier ou dans un système à bobines. Pendant le sciage, la pièce à travailler est sciée par le côté de largeur du fil à scier abrasif fixe. Le fil à scier abrasif fixe selon l'invention et la machine à scier associée prennent la place disponible entre les câbles à scier à trait large (trait supérieur à 4 mm) et les scies multifils à trait fin (inférieur à 0,25 mm).
PCT/EP2013/070710 2012-10-24 2013-10-04 Fil à scier abrasif fixe plat WO2014063910A1 (fr)

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EP12189756.5 2012-10-24
EP12189756 2012-10-24

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WO2014063910A1 true WO2014063910A1 (fr) 2014-05-01

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014198356A (ja) * 2013-03-29 2014-10-23 株式会社ノリタケカンパニーリミテド バンドソー
WO2016050508A1 (fr) * 2014-10-01 2016-04-07 Nv Bekaert Sa Élément de scie à alliage métallique déposé par placage laser
WO2016146343A1 (fr) * 2015-03-13 2016-09-22 Nv Bekaert Sa Procédé pour produire un fil de scie à abrasif fixe comprenant une couche de fixation en alliage métallique et fil résultant de ce dernier
US20170014921A1 (en) * 2015-07-15 2017-01-19 C4 Carbides Limited Tool Blades And Their Manufacture
JP6412284B1 (ja) * 2017-10-17 2018-10-24 株式会社Tkx マルチワイヤソー装置
US11135689B2 (en) 2015-07-15 2021-10-05 C4 Carbides Limited Tool blades and their manufacture
CN113857653A (zh) * 2021-12-03 2021-12-31 太原理工大学 一种超声辅助激光的表面改性装置

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DE3716943A1 (de) * 1987-05-20 1988-12-08 Hans J Scheel Verfahren und vorrichtung zum trennen von insbesondere stabfoermigem material
US5438973A (en) 1993-10-08 1995-08-08 Crystal Systems, Inc. Shaped blades
EP1027476A1 (fr) 1997-10-07 2000-08-16 Dialux Diamantwerkzeuge GmbH & Co. KG Outil de coupe et procede pour appliquer un revetement sur des outils de coupe
US6316744B1 (en) 1999-03-04 2001-11-13 Fraunhofer-Gesellschaft Zur Forderung Der Angewandten Forschung E.V. Machining head and process for the surface machining of workpieces by means of a laser beam
JP2003231063A (ja) 2002-02-12 2003-08-19 Kanai Hiroaki ソーワイヤ
WO2005089995A1 (fr) * 2004-02-18 2005-09-29 Societe D'exploitation Tarrerias Bonjean Procede de fabrication d'une lame tranchante et lame tranchante
JP2007044794A (ja) * 2005-08-09 2007-02-22 Kanai Hiroaki ワイヤソー用ワイヤ
EP2138263A2 (fr) * 2008-06-23 2009-12-30 The Stanley Works Procédé de fabrication d'une lame
JP2010167509A (ja) 2009-01-20 2010-08-05 Kanai Hiroaki 固定砥粒ソーワイヤ及び切断方法

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1216428A (en) 1968-02-08 1970-12-23 Remington Arms Co Inc Armored metal tools
DE8612523U1 (de) * 1986-05-07 1986-06-19 KADIA-Diamant Maschinen- und Werkzeugfabrik O. Kopp GmbH & Co, 7440 Nürtingen Diamantierter Sägedraht
DE3716943A1 (de) * 1987-05-20 1988-12-08 Hans J Scheel Verfahren und vorrichtung zum trennen von insbesondere stabfoermigem material
US5438973A (en) 1993-10-08 1995-08-08 Crystal Systems, Inc. Shaped blades
EP1027476A1 (fr) 1997-10-07 2000-08-16 Dialux Diamantwerkzeuge GmbH & Co. KG Outil de coupe et procede pour appliquer un revetement sur des outils de coupe
US6316744B1 (en) 1999-03-04 2001-11-13 Fraunhofer-Gesellschaft Zur Forderung Der Angewandten Forschung E.V. Machining head and process for the surface machining of workpieces by means of a laser beam
JP2003231063A (ja) 2002-02-12 2003-08-19 Kanai Hiroaki ソーワイヤ
WO2005089995A1 (fr) * 2004-02-18 2005-09-29 Societe D'exploitation Tarrerias Bonjean Procede de fabrication d'une lame tranchante et lame tranchante
JP2007044794A (ja) * 2005-08-09 2007-02-22 Kanai Hiroaki ワイヤソー用ワイヤ
EP2138263A2 (fr) * 2008-06-23 2009-12-30 The Stanley Works Procédé de fabrication d'une lame
JP2010167509A (ja) 2009-01-20 2010-08-05 Kanai Hiroaki 固定砥粒ソーワイヤ及び切断方法

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014198356A (ja) * 2013-03-29 2014-10-23 株式会社ノリタケカンパニーリミテド バンドソー
WO2016050508A1 (fr) * 2014-10-01 2016-04-07 Nv Bekaert Sa Élément de scie à alliage métallique déposé par placage laser
WO2016146343A1 (fr) * 2015-03-13 2016-09-22 Nv Bekaert Sa Procédé pour produire un fil de scie à abrasif fixe comprenant une couche de fixation en alliage métallique et fil résultant de ce dernier
US20170014921A1 (en) * 2015-07-15 2017-01-19 C4 Carbides Limited Tool Blades And Their Manufacture
US11135689B2 (en) 2015-07-15 2021-10-05 C4 Carbides Limited Tool blades and their manufacture
JP6412284B1 (ja) * 2017-10-17 2018-10-24 株式会社Tkx マルチワイヤソー装置
WO2019077790A1 (fr) * 2017-10-17 2019-04-25 株式会社Tkx Dispositif scie à fils multiples
JP2019075531A (ja) * 2017-10-17 2019-05-16 株式会社Tkx マルチワイヤソー装置
CN113857653A (zh) * 2021-12-03 2021-12-31 太原理工大学 一种超声辅助激光的表面改性装置

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