Ten reasons alloy saw blade wear

1, the phase change wear alloy blade at a certain friction during high speed cutting , the substrate or the material at temperatures above the phase transition temperature , causes the alloy saw blade with  cutting tools accelerated wear , thus losing the cutting ability . Such as high speed steels 500-600 °, ordinary steel 100 °, alloy steels 300-350 °, 65 manganese steel 200 ° temperature inside will result in the matrix phase transitions.
2 , the alloy microstructure in the welding temperature or other factors in the destruction of high -density ultra- fine particles in the welding alloy cold and hot temperatures , or high temperature , resulting in thicker alloy crystal , alloy cracking, deformation of the matrix alloy strength reduction and abrasion resistance .
3 , tool wear, cutting angle design and brick saws  material discrepancies due to different hardness and various types of plastic materials not targeted under the appropriate choice of alloy , and no matter according to the hardness of the cutting dry cutting angle of each side effect which reduces tool life .
4 , the oxidation of the alloy blade wear oxidation wear at 800 ° C or higher friction temperature, oxygen in the air and alloys of cobalt , tungsten carbide, titanium, tool wear due to oxidation occurs .
5, the impact of technology and precision grinding wear, alloy circular saw blades are precision cutting tools, any main and sub- edge blade with tape, face cutting straight face , or radial cutting rather than a cutting line, each one formed alloy cutting point or depth , and many other factors that reduce their effectiveness .
6 , diffusion wear diffusion is a chemical wear, diffusion wear is at a high cutting tool and the workpiece between the mutual diffusion of alloying elements , the tool material physical and mechanical properties of reduced lead increased tool wear . Carbide, titanium carbide increased in the tantalum carbide or other additives can be added to improve the matrix alloy and the temperature of diffusion and thus improve tool wear resistance and heat resistance.
7 , adhesive wear in the cutting of plastic material , the cutting and the rake face after the cutting work viscosity, the tool surface or partially lower strength adhesive particles or the  circular saw   workpiece to be cut so that the tool with grinding brush wear.
8 , improper maintenance or improper operation caused by wear and tear , each cutting equipment, cutting feed rate is not the same , while the alloy saw blade is designed according to different cutting material various angles , with inappropriate will reduce its effectiveness.
9 , mechanical wear workpiece or the tool cutting edge surface carved with shades of grooves caused by wear and tear. Workpiece or cutting edge tool and the workpiece with high hardness more than the smaller tool easy to wear, so the tool must have a higher hardness.
10 , the tool wear buildup feed speed is too fast or accuracy is not high , wheel selection and other factors, is not a good grinding blade with the cutting tool material during shock loading or poor toughness , tool face angle for each blade will have a loss factor with from.

Speed ​​Cutting Tools Introduction

 Since , and friction will no longer be a major source of cutting heat; same as cutting speed, flank at the elastic tile saw blade  deformation of the workpiece material to keep up with the deformation rate gradually reduced cutting speed, flank friction and thus also reduced, thereby to reduce cutting forces and heat generation beneficial effect. Therefore, in high-speed cutting, the main cutting heat will be derived chips, the temperature rise of the workpiece and the tool are very small, high-speed cutting is also known as "cold cutting." The high-speed machining We usually recommend a new interface standard called HSK. HSK tool by the German Institute of Aachen granite polishing pads  University specifically for the development of new high-speed machine tool - machine interface, and formed a tool for automatic and manual tool change, the central cooling and face cooling, ordinary type and compact 6 kinds of forms . HSK is a small taper (1:10) short hollow taper shank, tapered at the same time when using the contact face and to form a high contact stiffness. After analysis, although HSK spindle connected to the high-speed rotation, will also expand, but still able to maintain a good contact, rigidity of the connection speed of the interface is not affected.

diamond saw - blade manufacturing method

With the automotive, aviation and aerospace technology, the rapid development of the material properties and processing technology, increasing demand. New materials such as carbon fiber granite polishing pads  reinforced plastics, particle reinforced metal matrix composites (PRMMC) and ceramic materials are widely used. These materials have high strength, wear resistance, low thermal expansion coefficient and other characteristics, which determines them when machining tool life is very short. Resistant and stable development of novel superhard cutting tool is that many colleges and universities, research institutes and enterprises research. Diamond set mechanical, optical, thermal, acoustics, optics, and many other excellent performance in a, with a high hardness, low friction, high thermal conductivity, thermal expansion coefficient and chemical inertness is low, is an ideal material for tool manufacture. The recent development of a method for manufacturing diamond tools for an overview.
Application cited
(A) the processing of non-ferrous materials difficult to machineProcessing of copper, zinc, aluminum and other nonferrous metals and alloys, the material easy to adhere to the tool, processing difficulties. Using diamond low coefficient of friction, and non-ferrous metal affinity characteristics of small, diamond tool and the tool can effectively prevent the occurrence of metal bonding. Further, the elastic modulus of the diamond cutting edge portion is deformed when small, the cutting non-ferrous metal extrusion deformation is small, the cutting process can complete the small deformation, which can improve the surface quality.(2) the processing of non-metallic materials difficult to machineProcessing particle contains a lot of high hardness non-metallic materials difficult to machine, such as glass fiber reinforced plastic, filled silicone material, hard carbon fiber / epoxy composites, the material of the hard particles so that the tool wear serious, hard carbide cutting tools processing, and diamond tools, high hardness, wear resistance, and therefore processing efficiency.
(3) ultra-precision machiningWith the advent of modern integrated technology, precision machining direction to the development of the tool performance made some very high demand. Because diamond friction coefficient, low coefficient of thermal expansion, high thermal conductivity, can cut very thin chips, chip easily outflow affinity with other substances is small, easy to BUE, heat a small, high thermal conductivity, heat can be avoided of a blade and the workpiece, so the passivation edge, cutting deformation, the surface of higher quality can be obtained.
Method for producing diamond tools
Currently the main diamond processing polishing pads for granite  method has the following four categories: film coated tools, thick welded diamond tools, cutting tools and single crystal diamond sintered diamond tools.2.1 Thin Film Coated ToolsFilm coated tool rigidity and high-temperature characteristics in good collective material by chemical vapor deposition (CVD) tool made of diamond film deposition.As Si3N4 ceramics, WC-Co-based cemented carbide and the metal W thermal expansioncoefficient close to the diamond, heat generated when the film stress is small, it can be used as the base material of the cutter body. WC-Co-based alloy in the presence of Co binder phase easy to make the diamond film and the substrate is formed between the lower adhesion strength graphite, before the deposition in order to eliminate the need for pretreatment of Co (generally by acid etching to Co) .Chemical vapor deposition method is a method of using a gas containing the C source  Plate Compactor activated, the low gas pressure, the carbon atoms deposited in a certain area, the carbon atoms in the condensation, forming a diamond phase deposition process. Currently used for deposition of diamond by CVD include: microwave, hot filament, DC arc jet method.The advantage of diamond films can be applied to a variety of complex geometry of the tool, such as a blade with chip, end mills, reamers and drills; many non-metallic materials can be used to cut, cutting, cutting force, small deformation, smooth, abrasion slow, difficult to deform the workpiece for the workpiece material, tolerances small finishing. The main disadvantage is the diamond film and the substrate adhesion is poor, the diamond film does not have a re-grinding of the cutting tool.

diamond cutter in the hole machining pay

 Diamond tool manufacturers say that the saying goes: "not good goods cheaper, better goods are not cheap", on the  diamond blade circular saw other commodities that may true, but I am afraid that the tool tool is not at all clear; key is to match. On the job site of many factors: cutting objects such as equipment, quality requirements, quality of personnel and so on. Comprehensive assessment, sensible manner, the best use, just right, in order to save money, reduce costs, participation in the competition in the industry. This depends on the mastery of professional knowledge and understanding of information of similar products.
 In machining, drilling about its processing total of 1/3. Holes are semi-enclosed cutting, therefore, chip, heat diffusing, cutting fluids are more difficult to cast, and processing difficult. With scientific and technological advances in machinery parts, precision of the hole and surface roughness increasing demand, while the precision bore machining production often become critical, must be resolved.
Hole machining techniques should be used when processing research equipment and machine tools (so-called hardware), but also to study how to effectively use the equipment better application technology (the so-called software).
Definition and classification of the hole
What is a hole? According to the national standard GB1800-1979 requirements: Hole mainly refers to the cylindrical inner surface. Seen, refers broadly inclusive face hole. Holes are usually classified according to the following method:
(1) according to the shape of points. There cylindrical bore, tapered bore, drum-shaped hole, polygonal hole, spline holes and other shaped holes and special-shaped hole (such as bending holes) and so on. Among them, the most widely used cylindrical hole.
(2) According to the shape of points. A through hole and the blind hole (blind hole); hole (refer to the hole depth L and the diameter D of the hole than 5, L / D short depth to diameter ratio or aspect ratio; L / D = 5 ~ 20 are generally Deep, L / D> 20 ~ 30 is a medium deep, L / D> 30 ~ 100 called special deep) and shallow hole.
(3) according to the size of the aperture. A large hole (D> 100mm), common holes (D = 10 ~ 100mm), holes (D = 1 ~ 10mm) and micropores (D <1mm hole).
(4) according to the processing mechanism to points. There are machining, special processing, mechanical and electrical composite processing. Despite the special processing method more, but 4 inch saw blades  because the equipment is more expensive and processing efficiency is not high reason, either now or in the foreseeable future, conventional machining process will continue to be the primary means of holes.
(5) Press the machining precision points. With coarse holes (such as drilling and boring after a rough hole), semi-fine holes (such as reaming, thick hinge, semi-fine boring holes) and precision holes (such as precision hinge, finely drawn, grinding, honing, grinding holes), etc. Precision holes usually refers to the IT7 ~ IT6 tolerance level or above, the surface roughness Ra <0.8 ~ 0.4m hole in its geometric shape accuracy (eg roundness, cylindricity, straightness axis, etc.) General provisions in its dimensional tolerances with 1/2 to 1/3 range.
As aerospace, automotive, high-speed trains, wind power, electronics, home appliances, energy, mold, hydraulic, machine tools and precision machinery equipment manufacturing industry rapid development and upgrading of products, precision hole applications is increasing. Such as a hydraulic system widely used in a variety valve hole, high-pressure cylinder tube are some typical precision holes. Hole machining due to its own characteristics, processing more difficult, but more difficult machining precision holes.
Hole machining characteristics
Hole machining is a more complex process, the processing chip must be properly resolved, cooling and lubrication and guidance and other issues. Holes main features are:
(1) Due to the workpiece aperture size, length and shape constraints, the cutting tool corresponding slender, rigidity, and most of the cantilever clamping manner, the processing likely to cause deflection and vibration of the tool.
(2) difficult to eliminate chips. To improve the conditions of the chip and chip, the chip is bound to increase the groove, but this will make the lower strength and stiffness of the tool.
(3) difficult to introduce cutting fluid to the cutting area, the chip, between the tool and the workpiece hole wall friction is large, the cutting temperature is high, particularly in deep holes. Therefore, the cutting fluid in the hole machining has a special role. Cutting fluid rational selection and proper use of hole machining quality, tool life and cutting efficiency have a great impact.
Holes commonly used methods of cutting liquid supply pressure casting method and cooled French. The former is the most simple, but poor results for the fluid and cutting fluid consumed in large quantities. Internal cooling method used for hole drilling, deep hole drilling, ejector drilling, nesting knife and single edge boring reamer hole cutting tools, the need to make the tool for the fluid pressure within the cooling (oil) passage hole, oil and gas mixture is passed through this channel is fed to the cutting area, this method with less consumption of the cutting fluid, the tool structure is more complicated. Now, with the tool manufacturing technology, domestic and foreign companies have introduced a variety of tools with internal coolant supply high pressure fluid (oil) passage hole new tool for internal cooling method used to create the conditions.
Now research suggests that colde saw blade  cutting fluid used almost dry cutting "Steam bundle" spray cooling method is most effective, and cutting fluid consumption, low processing costs. "Steam beam" spray cooling is a certain pressure (0.3 ~ 1MPa) the cutting fluid air atomized and sprayed at high speed cutting zone, so that temperatures were in the region of the cutting droplets quickly swirl vaporized. Vaporization of the liquid will absorb the heat, which can greatly cut down the temperature region, while also taking the cutting zone cutting fluid and space heat and powder, improve the working environment. Practice has proved that the same amount of cutting fluid in the case of "steam beam" spray cooling at the same time by the casting method of the heat is absorbed in 1000. Therefore, it is not only to improve tool life, but also enable the cutting fluid consumption is greatly reduced. "Steam bundle" spray cooling both for automatic production line, but also for the general metal cutting.
(4) processing the cutting tool can not be directly observed, particularly in the processing of the pores and deep. Therefore, automatic monitoring and control is more important than the other processing methods.
(5) accuracy of hole size, geometry, precision, accuracy and surface roughness mutual position often due to the special nature of hole machining is difficult to control, but once the trial is successful, rather than other processing methods can be more regularly maintained.

planes of single crystal diamond tool selection

Diamond crystals are cubic plane, since each crystal form and surface atomic

arrangement atom density difference and the diamond cup grinding wheel  distance between the different

planes, resulting in a natural diamond crystal anisotropy, so the performance

of the diamond crystal surface only of the physical and mechanical different

performance, ease of manufacture and service life which are not the same, the

microstructure of the crystal surface damage strength are also significant

differences. Microscopic diamond crystals Hertz strength test method used to

determine, since the diamond is a typical brittle material, the strength values

​​are generally larger deviation depends on the morphology and distribution of

stress distribution range, so suitable analysis of probability theory. When the

effect of stress is the same, (110) crystal plane maximum probability of

damage, (111), followed by (100) crystal plane of the minimum probability of

breakage. Ie external force, (110) crystal face the most easily damaged, (111)

crystal face, followed by (100) the most difficult to break. Although the (110)

crystal plane grinding is higher than the diamond polishing pads  (100) crystal plane, but the

experimental results show that the (100) crystal face and the other plane has a

higher resistance to stress, corrosion, and thermal degradation capability.

Considering the combination of micro-strength, a (100) plane around the flank

of the tool to make easy tool edge grinding of high quality, easy to produce

microscopic chipping.
Normally be carried out according to requirements of the tool planes of the

single crystal diamond tool selection. In general, if the request to obtain the

highest strength diamond tool, should be used (100) surface as the tool before

the flank; if required resistance to mechanical wear diamond tool, the

selection of (110) crystal face as the tool before and after the diamond blade saws  flank; if

required chemical wear resistant diamond cutting tool, it is desirable use of

(110) crystal plane as the tool rake face, (100) crystal face as the flank, or

the front, flank are used (100) surface. These requirements are necessary to

achieve by means of crystal orientations.

Grinding wheel ten principles

 Wheel selection is often based on the three factors for the choice of grinding wheel: 1. Roughness; 2, life requirements; 3, the grinding efficiency requirements. Roughness is determined by the abrasive particle size, can be determined according to the roughness of the abrasive wheel size selection; life requirements and according to the requirements of grinding efficiency grinding wheel hardness can determine the cup grinding wheels  size and organizational good. We summarize a bit, wheel choices about ten principles.
1, the selection of coarse grained, fine grinding select granular.
2, sheet wheel should choose rubber or resin bond.
3, when the grinding and shaping grinding wheel hardness should be higher.
4, wheel fine grain size, the grinding wheel hardness should be lower.
5, form grinding, precision grinding should take the wheel tighter organization.
6, the diamond grinding wheel  workpiece grinding area is large, you should choose loose tissue of the wheel.
7, grinding nonferrous metals and other soft materials should be selected soft and loose wheel, grinding wheel in order to avoid congestion.
8, workpiece material hardness, should choose soft wheels, low hardness of workpiece material should be selected hard wheel.
9, grinding steel and  diamond cbn wheel other ductile material should be selected corundum abrasives; grinding cast iron, tungsten carbide and other brittle materials should be selected silicon carbide abrasive.
10, the grinding contact area should choose soft wheel. Therefore, internal grinding and face grinding wheel hardness than cylindrical grinding wheel hardness is low.

What are the current market and diamond tools

At present, China's use of abrasive machining, geology drill and stone cutting tools manufacturing technology level has been greatly improved, the product has formed, standardization, variety specification is complete, stable product quality, some products in the  diamond blade saws international market certain competitiveness. All kinds of diamond tools also been widely used in various industries, and achieved significant economic benefits, but on the whole diamond tools industry, still need to improve the industrial planning, broaden application areas, creating an international brand.
1 Industry Planning: strengthen macro-control management
Because the blind development, hardware and tools, especially diamond tools production layout appears scattered and  masonry saw blades  chaotic situation everywhere, generally small-scale producers, production is not centralized, process technology, the lack of market competitiveness, product quality tools sales market instability, competition disorder, price confusion, economic efficiency is not high.
(2) Product Development: Widening the application areas of diamond
The current domestic production tools as well as new product development, technology research and other aspects of insufficient capital investment, to increase tool industry investment, pay close attention to new product development and new technologies, promotion of new technology and continue to broaden the field of application of diamond to enhance diamond tools industry overall technological level and market competitiveness, variety, quality of survival, to scientific and technological progress and development.
Tools to meet the needs of the diamond core drills  market at home and abroad, we must accelerate the development of new products, improve product quality, increase product variety and improve production. In recent years, machinery, gems, medical equipment, wood, glass, steel, stone handicrafts, ceramics and composites processing of non-metallic brittle materials the field of diamond tools demand increases every year, at present, these products are domestic or imported, must as soon as possible developed a variety of high-quality range of tools to replace imports.
Currently urgent need to develop products: oil drilling PDC bits, stone polishing with diamond grinding blocks, core bits, diamond honing stone, diamond film coating tools, diamond wheel, rubber plastic-bonded diamond tools, PCD diamond tools, diamond needle, nozzle, diamond heat sink and transistors and other products. To ensure the quality of their products, we must accelerate new technologies, promotion of new technology, such as vacuum welding technology, spark sintering technology, uniform technology of diamond, diamond-plated iridium technology and metal bonding technology, laser welding technology.
3 development of the industry: joint build international brands
Enterprise, innovation is advanced technology, and constantly improve the production process, reduce production costs and improve economic efficiency. Take the group or joint venture on the road, the formation of several large enterprise groups, to guide development of the industry, to create their own brand, and actively participate in international competition. Relying on technological progress, increase scientific and technological input, update equipment, pay close attention to new technologies, new processes, new product research and promotion, to improve tool substrate material usage, accelerate the development of China's hardware tools industry to further enhance economic efficiency and overall level of technology.