Recent development status and prospects of domestic diamond circular saw blades
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1. Recent development status of diamond circular saw blade 1.1 Breakthrough and development of key technologies
In recent years, with the breakthrough of key technologies such as new pre-alloyed powder, flexible processing and laser welding, diamond circular saw blades have been made in the fields of stone, construction, geology, petroleum, mining, electric power, transportation, national defense, etc. More important applications. At present, domestic diamond circular saw blades have partially replaced imported similar products, which are basically undertaken by several manufacturers such as Black Cyclone, Yutian and Haien. The saw blades produced by these companies account for more than 85% of the entire stone market capacity. The international market also has a certain competitive advantage. With the advancement of synthetic technology, more excellent diamond circular saw blades will be researched and applied to promote their progress and upgrade.
1.2 Diversification, serialization and standardization of product varieties
Diamond circular saw blades are available in a wide variety of applications. According to its application, it is divided into: circular saw blade for stone cutting, circular saw blade for wood cutting, circular saw blade for cutting asphalt and concrete, circular saw blade for refractory cutting, and circular saw blade for art pattern carving. The diameter ranges from small hand-cut pieces (Φ105mm) to large circular saw blades (Φ2500mm), which are used for cutting different sizes of materials. Distinguish from the production process: laser welded diamond circular saw blades, electroplated circular saw blades, powder sintered saw blades, etc. Nowadays, in the aspects of stone processing, ceramic cutting, home decoration, etc., diamond circular saw blades form a rich and diverse product series. In each product series, a new and complete product system can be formed according to the different cutting objects, and both Formed a large-scale, professional production.
1.3 Research Status of Diamond Circular Saw Blades in China
According to market research and analysis, in the various engineering fields using diamond circular saw blades, the common base diamond circular saw blades are still the most widely used. It can also be found that ordinary matrix diamond circular saw blades can meet most cutting needs, but There are still many problems with the saw blade, which affects the cost reduction of the saw blade and the improvement of the cutting quality.
In view of the many problems existing in the current circular saw blade, some people have studied the influence of the composition of the carcass of the cutter head, the cobalt content, the diamond, the different tungsten carbide powder and the sintering process on the sharpness and the life of the saw blade. Sharp and cut-resistant concrete circular saw blade. Some people have analyzed the distribution of diamond on the working face of the diamond circular saw blade and the movement characteristics of the saw blade. The distance between the diamonds on the working surface of the saw blade and the trajectory of the diamond are obtained. Based on this, the calculation formula of the thickness of a single diamond is derived, and the relationship between the cutting thickness and the sawing parameters and the nodal structure is discussed. Others have comprehensively introduced the related results of optimizing the diamond circular saw blade base and sawtooth structure at home and abroad, and analyzed the characteristics, production value and existence of various saw blade base and sawtooth structure which are resistant to side wear and stress deformation and improved cooling performance. problem.
In today's increasingly fierce competition, the distinctive and diversified diamond circular saw blade products will undoubtedly have stronger vitality and attractiveness, and more market calls. Industry-related companies must manage their own characteristics, while keeping up with market developments and requirements, in order to stand in the market.
2 Diamond circular saw blade development prospects 2.1 Improve cutting quality and saw blade life
In order to save stone and reduce environmental pollution, the diamond circular saw blade is developing in a thin direction. In the working process, because the circular saw blade is subjected to external loads such as centrifugal force, sawing force and sawing heat, the saw blade has a diameter-to-thickness ratio of more than 200. It is a typical ultra-thin part and is prone to axial deformation buckling. The stress at the bottom of the water tank is large, which is easy to cause cracks and fractures of the saw blade, leading to early damage of the saw blade agglomeration and a decrease in the life of the saw blade.
Therefore, improving the cutting quality of the saw blade and extending the service life of the saw blade has become one of the hotspots of current research. Some people have found that adding auxiliary abrasives with appropriate particle size and concentration can not only improve the life of the saw blade, but also improve its sharpness. The service life of the diamond saw blade can be increased by more than 150%, and the cutting efficiency is improved by about 40%. According to the fatigue failure theorem of mechanical components, He Zhijian reduces the stress of the saw blade by reducing the stress of the root of the saw blade under the same cutting force and improving the service life of the saw blade.
The application level of diamond circular saw blade directly determines the level of stone processing in a country. It is a consensus of all countries in the world to develop various types of high-quality, high-efficiency diamond circular saw blades and improve the development of cutting technology. At present, China is in a critical period of manufacturing a big country to a strong country. In the future development of China's machinery industry, saw blade cutting is a key factor.
2.2 Prevent resonance and reduce noise
Diamond circular saw blades generate resonance and noise during sawing. The periodic excitation of the saw teeth causes the saw blade to vibrate laterally, which increases the wear of the segments and leads to a shortened service life. Saw blades usually produce harsh noise when sawing, and the noise peak sound pressure level can exceed 120dBA. Even the small-diameter diamond disc hand saw, the radiated noise is very harsh, which has certain fitness for the operator. harm.
Domestic researchers have carried out detailed and in-depth research on the vibration characteristics and dynamic stability of circular saw blades, and proposed the mechanism of the instability of circular saw blades. When the circular saw blade reaches the critical speed instability state, even if the lateral force value is very small, it will cause a large lateral swing of the circular saw blade, which may lead to a series of more serious consequences. In diamond work, aerodynamic noise plays an important role in some occasions (tooth tip noise, eddy current noise, exhaust noise, etc.). When the circular saw blade is in a high-speed rotation state and the separation frequency of the air vortex is close to a certain natural frequency of the saw blade, resonance noise is generated.
The use of an external auxiliary support controller to increase the lateral stiffness of the saw blade not only reduces resonance and noise, but also improves sawing stability. As a result, the working efficiency of the circular saw blade has been significantly improved, and the threat to the physical and mental health of the operator has been greatly reduced. In addition, combined with uniform distribution/ordered alignment technology, powder ultra-fine reduction and low oxidation technology, the vibration and noise problems of diamond circular saw blades will be improved to a certain extent, the microstructure of the alloy will be more adequate, and the sawtooth size will be smaller. .
2.3 Matrix innovation and structural optimization
With the increasing use of stone and the increasing awareness of human environmental protection, diamond circular saw blade cutting technology is developing towards improving cutting efficiency, reducing production cost, saving stone resources and reducing environmental pollution. One of the important technologies The trend is matrix innovation and structural optimization.
Some domestic researchers have used the finite element analysis software ANSYS to optimize the design of an ultra-thin diamond circular saw blade structure suitable for high-speed sawing. Other researchers based on the innovative design principle of the saw blade, the analysis of the structure and function of the saw, the circular saw blade is decomposed into the cutting function module, the supporting function module and the driving function module, and the design scheme of the new combined diamond circular saw blade base is proposed. . The optimized combined circular saw blade has a mass reduction of 3.048kg, a natural frequency increase of 3.235Hz, a reduction in the diameter and thickness of the circular saw blade, a more stable dynamic performance and a more reasonable structure. Some researchers have found in the study of the dynamic characteristics of diamond saw blades that the stiffness of the saw blade can be improved by changing the geometric parameters of the saw blade, which can extend the service life of the saw blade and improve the quality of the saw.
Compared with the international, the comprehensive quality of the domestic circular saw blade matrix still has a certain gap. The technology of using a large number of saw blades to process stone is still a manual level, and intelligent applications are not popular enough. Looking into the future, we must improve the performance and life of our products, rely on the advancement of superhard materials such as diamonds, improve the flexible processing, laser welding and other technologies, and comprehensively improve the overall manufacturing level and application level of China's diamond circular saw blades.
3 Conclusion
Faced with the rapid development of diamond circular saw blades, we need to be calm and think hard. We must realize that the development of diamond circular saw blades must be an all-round, high-level, sustainable development, not just to maintain a single benefit. We must be based on the present and focus on the future. This is very important for the Chinese diamond circular saw blade industry.
The development of diamond circular saw blades is closely related to super-hard materials. We will continue to develop high-performance diamond circular saw blades while strengthening the development of super-hard materials, and organically combine them to promote the development of the saw blade industry. Single crystal diamond, cubic boron nitride, various polycrystals, etc. can be applied to diamond circular saw blades, expanding their application fields and scopes and forming a composite saw blade, which can open up a benign situation of a new diamond circular saw blade.
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