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In recent years, researchers have conducted extensive research on manufacturing cutter heads for certain hard-to-machine materials with high hardness, and the cutting performance of the cutter head has been improved. However, the problem of low diamond utilization in the cutter head has not been well solved, and the manufacturing cost is high. This paper proposes a new method for the manufacture of diamond circular saw blade heads by electroplating and powder metallurgy, and conducts preliminary research and discussion on related technical issues.
Manufacturing method
1. Preparation of diamond composite sheet by electroplating method 1mm thick copper plate is used as the base body, which is firmly clamped by the clamp after degreasing and cleaning. The fixture divides the copper plate into a plurality of small pieces of 24 mm × 12 mm, and each small piece surface is laminated by a composite electrodeposited diamond to form a composite piece. After the copper plate is used as the cathode and the Ni or Ni-Co metal is deposited by electric current, a layer of diamond (called upper sand) is evenly sprinkled on the flat copper plate, and the sand is deposited at a small current density for a certain period of time, and then the current is increased. The density is thickened and plated. When most or all of the diamond is buried by the deposited metal, the jig is taken out, cleaned with water, and the deposited composite sheet is peeled off from the copper plate substrate, and dried for use. Figure 2 is a surface topography of a diamond composite sheet produced by electroplating.
2, powder metallurgy bonding diamond composite sheet Select several metal powder, low melting point copper powder, supplemented by cheap metal powder. Different materials for processing stone, you need to choose different metal powder and ratio.
3, the choice of mold mode The mold size is 24mm × 12mm × 9mm. The diamond composite sheet was used to replace the original abrasive layer. The size of each composite sheet was 24 mm × 12 mm. The thickness of the composite sheet was mainly determined by the thick deposition time and current density during the electroplating process, and the diameter of the diamond abrasive grains used in the composite sheet. similar. The number of layers to be assembled can be adjusted according to the material of the processed stone. The larger the processed stone grain, the smaller the number of layers.
4. Selection of sintering process Since the low melting point metal powder is mainly used as the binder, a lower sintering temperature can be adopted, and the degree of thermal damage of the diamond can be reduced compared to the ordinary powder metallurgy sintering method. Cold press forming, vacuum sintering process can also be used.
Main features of the new method
1. Reducing the thermal damage of diamond. The diamond composite sheet has no thermal damage to diamond. When using metal powder hot-pressing, a relatively low hot pressing temperature can be used, which can reduce the thermal damage to diamond to a certain extent. .
2. The difficulty of sintering the cutter head is reduced. For the diamond saw blade head manufactured by the process, the problem of the abrasive holding force is determined by the electroplating process, and it is easy to obtain a good holding force. Diamond oxidation problems can be disregarded and the sintering temperature is lower, thus reducing the difficulty of sintering.
3. The sharpness of the manufactured cutter head is good. The sharpness of the electroplated diamond product is good, which can improve the processing efficiency.
4. High concentration of electroplated diamond products can be used with high abrasive concentration, which cannot be achieved by powder metallurgy.
5, the manufacturing cost is lower The preparation of electroplated diamond composite sheet can be selected II, III low grade diamond, which can greatly reduce the manufacturing cost of diamond circular saw blade.
discuss
1. Quality problems of electroplated diamond composite sheets
Since the electroplated composite sheet is used instead of the diamond abrasive layer, the diamond on the composite sheet becomes the main body of the sawing process. The quality of the composite sheet is the basis for the manufacturing of the cutter head and plays a key role in the quality of the final cutter head. The quality of the composite sheet depends on the quality of the diamond used in the plating and the process control of the plating process.
The plating process is required to deposit fine carcass material and have good grip on the diamond cured therein. This depends on the choice of the deposited alloy, the choice of plating process parameters, the sanding process, etc., wherein the sanding process determines the diamond concentration of the composite sheet. Electroplated products allow for higher abrasive concentrations, which is a major advantage. The process determines the concentration of diamond in a composite sheet containing diamond of different particle sizes and grades by a sawing test.
2. Bonding problem between composite sheet and metal bond
The bonding between the composite sheet and the metal bond is connected by sintering of the metal powder, so the bonding force between the metal powder layer and the abrasive layer of the composite sheet is very important, which determines the feasibility of the process, and It has an important influence on the sawing processability. Studies have shown that if the diamond is deeply embedded in the electroplated composite sheet, the connection between the metal and the composite sheet is converted into a connection between the electroplated carcass metal material and the powder metallurgy metal material, and the bonding force between the two is good. Can bear the load when sawing.
Conclusion
In summary, the cutter head manufactured by the process has the advantages of low cost and high processing efficiency, and the production application thereof will produce good economic benefits. Therefore, the manufacture of diamond circular saw blade heads by electroplating and powder metallurgy combined method has certain promotion and application value.
A new method for manufacturing diamond circular saw blade
At present, the manufacture of diamond circular saw blade heads is generally carried out by powder metallurgy press molding process in foreign countries. There are several unfavorable factors in the process: 1) the diamond used in the process requires a higher grade; 2) the powder metallurgy press head has stricter requirements on the design and process of the carcass formula, otherwise the diamond is peeled off. It will be very common, resulting in great waste; 3) The powder metallurgy production process will cause thermal damage to the diamond to affect the original properties of the diamond and further affect the cutting performance of the saw blade.