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Comparison of brazed diamond wire saw and electroplated wire saw
Publish Date:2020-10-16
Brazed diamond wire saw bead. The diamond on the bead is firmly held on the steel base by brazing. This method can make the diamond particles evenly distributed. Each diamond can be cut effectively, thereby reducing the amount of diamond used, avoiding waste, and at the same time enabling unobstructed chipping. Practice shows that the cutting efficiency of brazed diamond beads is 4 times that of electroplated diamond beads.
Comparison of brazed diamond bead wire saw and electroplated diamond bead wire saw:
Conventional electroplating process and brazing process are specialized in manufacturing single-layer diamond tools. Let's compare the beading characteristics of these two different processes.
Dimensional accuracy: Both electroplating and brazing processes are based on steel base. Each uses a different process to coat a layer of diamond on the steel base. The diamond coating accuracy of the two is similar. However, for larger tools, the electroplating process is a bit more than the brazing process. The reason is that the brazing process inevitably bears high temperature heating (such as 800-1000°C), so that the steel base undergoes a slight deformation during the process of thermal expansion and contraction, which is enough to affect the dimensional accuracy of the tool.
Grinding efficiency: The diamond open of brazed diamond tools can be 2/3 of the height of the diamond, so the grinding efficiency is high, and it is beneficial to scouring the wear debris, and the surface abrasive particles are not easy to lose the grinding ability due to clogging. Chip removal performance is a very obvious advantage of brazed diamond beads.
Diamond particle arrangement: electroplated single-layer diamond is sanded by buried diamond method, and the diamonds are arranged in a dense and disordered state. Brazing diamond particles can be arranged in an orderly manner, and the diamond can be sparse or dense. Brazing diamond beads not only save diamonds in practical applications, but also help adapt to different grinding or other use requirements.
Diamond tool life: Brazing is the metallurgical combination of diamond particles and brazing alloy, that is, they are firmly welded, while the diamond particles in electroplated diamond tools are only embedded by electroplated metal deposition, and there is no metallurgical bond between the two. When the diamond wear exceeds the large section, it will inevitably fall off, so the brazed diamond wire saw has a longer life.
Impact on diamond performance: The diamond in brazed diamond tools must withstand high temperatures, although for a short time, but it is enough to reduce the strength of diamond, so diamond with good thermal stability and brazing alloy that does not react strongly with the diamond surface must be selected. If the heating time is long, or the material is selected improperly, it will cause damage to the diamond surface, and some may even destroy the bond between the two. However, electroplating does not have that high requirement, so in 1977, people could make electroplated diamond wire saw products.
Production cycle: Due to the deposition and thickening of the electroplated layer, it is generally carried out at a speed of 5-1-um/h, which determines that the production cycle of electroplated diamond tools is very long; the manufacture of brazed diamond tools is highly efficient, and its speed depends on The heating method is appropriate, and it can be completed in about ten minutes, and it has nothing to do with the thickness of the selected diamond particles.
The shape of the matrix of electroplated diamond beads is convex; the shape of the matrix of sintered diamond beads is gentle; and the brazed diamond beads are wet to the diamond due to brazing. The carcass shape is concave. Due to the different carcass shapes, the diamond blade height of electroplated beads is limited to 1/3 of the abrasive grain height: while the blade height of brazed beads can reach 2/3. Each diamond can work effectively, and the cutting performance is improved. When sawing granite and marble, compared with electroplated diamond beads, its life is also good.
Generally speaking, electroplated diamond wire saws have the advantages of simple production process and easy entry, but the shortcomings are also very obvious. For example, high diamond concentration leads to high cost, simple production process, but it takes too long, low cutting efficiency and short life. The brazed diamond wire saw has the characteristics of high efficiency, long life, saving use of diamond, and short production time. However, there are also disadvantages, such as not resistant to high temperatures, large changes in the size of the brazing surface, and need professional brazing machinery and finish under vacuum conditions and so on.
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