CN113000934A - Brazing diamond saw blade for cutting casting material and cutting process thereof - Google Patents

Abstract

The invention belongs to the field of saw blades, and particularly discloses a brazed diamond saw blade for cutting casting materials and a cutting process thereof. The invention is designed based on the structure and the abrasive grain parameters of the novel brazing diamond saw blade, particularly improves the sizes of slots among sectional type cutter heads, the performance of brazing diamonds and the distribution parameters, and matches with a proper cutting process, so that the invention not only can effectively cut conventional iron castings, including gray cast iron, nodular cast iron, silicon-molybdenum-containing cast iron and the like, but also can particularly process hard-to-process materials with high hardness and high toughness, such as high-nickel cast iron, cast stainless steel and the like.

Description

Brazing diamond saw blade for cutting casting material and cutting process thereof

Technical Field

The invention belongs to the field of saw blades, and particularly relates to a brazing diamond saw blade for cutting a casting material and a process for cutting the casting material based on the brazing diamond saw blade.

Background

Cast iron, cast steel and other materials belong to casting materials. Although casting materials are widely applied, classified and have large material performance difference, all casting processes adopted by the casting materials in workpiece preparation can form certain risers, flashes, burrs and the like, and the risers, the flashes, the burrs and the like need to be cut or polished for removal. With the popularization of automatic cutting and polishing robots and special machines, the automatic machining range for the operations of cutting, removing dead heads, burrs and the like of castings is wider and wider at present, and a brazing diamond saw blade, an electroplating diamond saw blade or a sintering diamond saw blade is mostly prepared, wherein the brazing diamond saw blade is mainly used, and the automatic cutting and polishing robot is particularly suitable for automatically cutting casting materials due to the high efficiency, stable performance and basically unchanged size in the machining process.

The casting materials are various, the conventional brazing diamond saw blade can meet the cutting requirements for conventional gray cast iron, medium and low grade nodular cast iron, silicon-molybdenum-containing cast iron and the like, but for materials with high hardness, high toughness and strong adhesion to diamond, such as high-nickel cast iron, cast stainless steel and the like, the conventional brazing diamond saw blade is low in cutting efficiency, unstable in cutting, easy to adhere to chips on the surface, high in service life fluctuation and not beneficial to the application of a brazing diamond tool in the field.

In addition, for cast iron and cast steel materials which are difficult to process, a better matched brazed diamond saw blade is not available, and the cutting process matched with automatic equipment is difficult to be matched ideally. However, the cutting process is also critical to affect the cutting performance, such as the range of the saw blade rotation speed, the feeding mode, the cooling mode of the saw blade, and the like. How to effectively realize a stable cutting process in a limited cutting processing space to match with a special novel brazing diamond cutting saw blade is the key for solving the problem.

At present, reports related to brazing diamond saw blades suitable for the field of cutting cast iron or cast steel and the application of the cutting process to automatic cutting of cast iron and cast steel materials are not seen.

Disclosure of Invention

Aiming at the problems of low cutting efficiency, easy burning, easy adhesion and blockage on the surface of the saw blade, short service life and the like of the traditional brazing diamond saw blade when cutting casting materials such as high-nickel cast iron, cast stainless steel and the like, the invention is designed based on the structure and the abrasive particle parameters of the novel brazing diamond saw blade and matched with a proper cutting process so as to achieve the purposes of good heat dissipation during cutting, stable cutting and long cutting service life. The brazing diamond saw blade and the corresponding cutting process thereof can effectively improve the cutting performance of the saw blade, obviously reduce the cutting cost and have higher economic benefit.

In order to achieve the purpose of the invention, the invention adopts the following technical scheme:

a brazing diamond saw blade for cutting casting materials comprises a saw blade substrate, wherein a plurality of sectional type tool bits formed by interval of slots are arranged on the edge of the saw blade substrate, a diamond distribution area is arranged on the outer edge of each sectional type tool bit, diamonds are brazed in the diamond distribution areas, and through holes are formed in the sectional type tool bits; wherein the width of the slot is not more than 3mm, and the depth is 12 mm-30 mm; the granularity of the diamond is 20-40 meshes, the average static compressive strength is not lower than 350N, and the cold impact breakage rate is not lower than 82%; and the diamond distribution density of the diamond distribution area is 55 particles/cm²About 120 particles/cm²。

Furthermore, the width of the slot is 1.8-2.5 mm, and the depth is 15-20 mm; the granularity of the diamond is 25-35 meshes; and the diamond distribution density of the diamond distribution area is 70 particles/cm²95 particles/cm²。

Further, the slot is key-shaped.

Further, the through hole is tangent to the arc boundary of the diamond cloth area.

Further, the diamonds in the diamond cloth area are positioned at the top end of the through hole and tangent to the through hole.

Further, the diamond distribution areas are positioned on two opposite side surfaces of the sectional type tool bit and the edge surface of the top end of the sectional type tool bit; wherein the cloth width of the diamond cloth area on the side surface is 3-5 mm.

Further, in the diamond distribution area, the average embedding depth of the solder is 30% -50% of the grain size of the diamond.

Further, the number of the sectional type cutter heads is 24-36; 3-4 through holes are uniformly formed in each sectional type cutter head; wherein the aperture of the through hole is 3 mm-4 mm.

Further, the outer diameter of the saw blade matrix is 300 mm-500 mm, the thickness is 2.5 mm-3 mm, and the material is 50a steel or a steel grade with comprehensive performance higher than 50a steel; the length of the sectional type cutter head is 35-40 mm.

The invention also provides a process method for cutting casting materials based on the brazing diamond saw blade, which comprises the following steps:

a saw blade fixing step: clamping and fixing any one of the brazing diamond saw blades by adopting a main shaft and a flange of a cutting robot; generally, the saw blade is clamped and fixed through a saw blade hole arranged in the center of a saw blade base body;

and working parameter control: regulating and controlling the rotating speed of a main shaft of the cutting robot to be 2000 rpm-4500 rpm, and the power of a main shaft motor to be not lower than 4 kW;

grinding, cooling and spraying: controlling the pressure of the cooling liquid to be more than 0.4MPa, and respectively spraying the cooling liquid to the main spraying area and the auxiliary spraying area; the main spraying area is a cutting part of the brazing diamond saw blade contacted with a workpiece to be cut, and the auxiliary spraying area is the front end of the main spraying area and is not more than the main spraying area and is positioned opposite to the brazing diamond saw blade;

and starting the cutting robot under the conditions of the working parameter control step and the grinding, cooling and spraying step, and cutting the workpiece to be cut by adopting the brazing diamond saw blade.

The brazing diamond saw blade and the process for cutting casting materials by using the brazing diamond saw blade designed by the invention can effectively cut conventional iron castings, including gray cast iron, nodular cast iron, silicon-molybdenum-containing cast iron and the like, and can also be used for processing high-nickel cast iron, cast stainless steel and other hard-to-process materials with high hardness and high toughness, and the automatic cutting process optimization is adopted, so that the cutting stability is achieved, the saw blade cutting efficiency is high, the cutting efficiency is at least improved by 35% compared with that of a commercially available resin grinding wheel, the cut burn is small or not, the service life of the saw blade is long, the overall cutting comprehensive cost is reduced by more than 20%, and the process is. The novel brazing diamond saw blade provided by the invention has higher cost performance than the conventional brazing saw blade, and has higher economic benefit than other types of saw blades such as an electroplated diamond saw blade, a sintered diamond saw blade and a resin grinding wheel.

Drawings

The above and other aspects, features and advantages of embodiments of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a schematic structural view of a brazed diamond saw blade according to an embodiment of the present invention;

FIG. 2 is an enlarged view of a portion of area A of FIG. 1;

fig. 3 is a schematic view of a brazed diamond saw blade according to an embodiment of the present invention in a state when cutting a cast material.

Detailed Description

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the specific embodiments set forth herein. Rather, these embodiments are provided to explain the principles of the invention and its practical application to thereby enable others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use contemplated. In the drawings, the shapes and sizes of elements may be exaggerated for clarity, and the same reference numerals will be used throughout to designate the same or similar elements.

It should be noted that, in the present application, the terms "upper", "lower", "left", "right", "front", "rear", "top", "bottom", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings. These terms are used primarily to better describe the invention and its embodiments and are not intended to limit the indicated devices, elements or components to a particular orientation or to be constructed and operated in a particular orientation.

Moreover, some of the above terms may be used to indicate other meanings besides the orientation or positional relationship, for example, the term "on" may also be used to indicate some kind of attachment or connection relationship in some cases. The specific meanings of these terms in the present invention can be understood by those skilled in the art as appropriate.

Furthermore, the terms "disposed," "provided," and "connected" are to be construed broadly. For example, it may be a fixed connection, a removable connection, or a unitary construction; can be a mechanical connection, or an electrical connection; may be directly connected, or indirectly connected through intervening media, or may be in internal communication between two devices, elements or components. The specific meanings of the above terms in the present invention can be understood by those of ordinary skill in the art according to specific situations.

Referring specifically to fig. 1 and 2, the present invention provides a brazing diamond saw blade for cutting cast materials, which includes a blade body 1, and a plurality of segment type cutting tips 2 are provided at the edge of the blade body 1, and the segment type cutting tips 2 are spaced apart by a slit 3.

Furthermore, a diamond distribution area 21 is arranged on the outer edge of each sectional type tool bit 2, and diamonds 4 are brazed in the diamond distribution area 21; the sectional type tool bit 2 is also provided with a plurality of through holes 22.

The sizing of the slot 3 is critical to the good application of the brazed diamond saw blade provided by the present invention to cutting cast materials. The width of the slot 3 is controlled not to exceed 3mm, and preferably 1.8 mm-2.5 mm; the depth is 12mm to 30mm, preferably 15mm to 20 mm. Specifically width W and depth L in fig. 2. When cutting metal materials, particularly cast steel materials which are difficult to process, the brazing diamond saw blade is tough and difficult to discharge cuttings when feeding, the slot 3 can become a scrap containing space by controlling a certain slot width, and the brazing diamond saw blade can have a certain cutting interval, so that the heat dissipation is facilitated. However, when the slot 3 is too wide, the distance between the two sectional type cutter heads 2 is too large, and the brazing diamond saw blade is possibly blocked due to too large cutting resistance in heavy load, so that the use performance of the motor and the main shaft is influenced; and when the slot opening 3 is too narrow, the processing difficulty is high, and the chip removal is not facilitated. In addition, the depth of the slot 3 is also one of factors influencing the cutting stability, the depth is too large, the strength of the saw blade is low, and deflection is easy to occur; and the depth is too small, the internal stress of the brazed diamond saw blade is difficult to release completely after brazing, the internal stress of the saw blade is large, and the saw blade is easy to deform during cutting. Therefore, the data are obtained according to cutting practice, and the parameter ranges are obtained according to further optimization of characteristics of the cut castings and the castings difficult to machine.

The properties of the brazed diamonds 4 in the diamond cloth region 21, as well as layout related parameters, are also key control criteria for the brazed diamond saw blade. The grain size of the diamond 4 is controlled to be 20 to 40 meshes, preferably 25 to 35 meshes. When the brazing diamond saw blade provided by the invention is applied, theoretically, under a certain cutting condition, the larger the particles of the brazing diamond 4 on the sectional type tool bit 2 are, the larger the material removal amount of a workpiece to be cut is, the higher the processing efficiency is, but because the high-nickel cast iron and the cast stainless steel material wait for the high adhesion of the workpiece to be cut, the larger material removal amount means larger cutting heat generation, means larger friction and wear generation, and on the contrary, the surface adhesion and wear of the diamond 4 are more likely to be caused. Therefore, in the range of the invention, the granularity of the diamond 4 is selected to be between 20 meshes and 40 meshes, and the cast iron and cast steel material is suitable to be cut; particularly, 25 to 35 mesh is most preferable.

The brazing diamond saw blade for cutting the casting material provided by the invention has the advantages that the average static compressive strength of the diamond 4 is not lower than 350N, and the cold impact breakage rate (namely TI value) is not lower than 82%. The high static compressive strength and cold shock resistance of the diamond 4 are effective guarantee for guaranteeing high efficiency and long service life of the brazed diamond saw blade cutting casting material, and a certain crystal form can be still maintained after the diamond 4 is partially micro-crushed, so that the self-sharpening effect is achieved, and the cutting service life is prolonged.

The distribution density of the diamond 4 brazed in the diamond distribution area 21 is 55 particles/cm²About 120 particles/cm²Preferably 70 particles/cm²95 particles/cm². The key point of cutting of the diamond 4 is heat dissipation and chip removal, the more the surface diamonds 4 are, the cutting removal amount is increased during processing, but the surface size of the saw blade matrix 1 is fixed, the increase of the diamonds 4 easily causes the interval between the diamonds 4 to be too small, correspondingly, the exposure is also reduced, the heat dissipation space is reduced, and the cutting efficiency and the service life are influenced. In order to ensure effective cutting and ensure cutting efficiency, 55 particles/cm are adopted²About 120 particles/cm²The distribution density of (a); particularly, for the difficult-to-process material, 70 particles/cm is selected²95 particles/cm²More suitably.

In the brazed diamond saw blade of the present invention, each segment has two side surfaces in the upper and lower directions in a flat display state, and a tip edge surface connecting the two side surfaces. Accordingly, the diamond cloth regions 21 are located on both side surfaces and the top edge surface, and the diamond cloth regions 21 are distributed over the entire area of the top edge surface and a partial area (also referred to as a cloth width) of the top edge surface adjacent to both side surfaces. Generally, the cloth width is controlled not to be too large, and the too large cloth width can increase the side friction area and increase the heat generation, but is not beneficial to cutting processing. On the premise of ensuring smooth cutting, the cloth width of 3-5 mm can meet the cutting requirement.

In the diamond distribution area 21, the average embedding depth of the solder is controlled to be 30-50% of the grain diameter of the diamond 4. Under the conventional condition, the diamond 4 can achieve the holding effect by being embedded by more than 30 percent of the solder, so that the diamond 4 is high in exposure and sharp in use, and can achieve a better heat dissipation effect by matching with the adaptive cloth density; however, since the cast iron material has high cutting strength, the edge of the brazed diamond saw blade is subjected to heavy cutting load, and if the exposure is high, the abrasive grains are easily broken and broken, a certain embedding thickness needs to be increased, and based on the comprehensive consideration of the cutting efficiency and the cutting life, the embedding depth of 30-50% is appropriate, and preferably 40-50%.

Generally, the diamond is brazed in the diamond cloth area by adopting nickel-based alloy solder.

The outer edge of the saw blade body 1 is provided with segment-shaped cutting heads 2, a plurality of segment-shaped cutting heads 2 are separated by slots 3, and the number of the separation (i.e. the number of segment-shaped cutting heads 2) is related to the material of the work piece to be cut. The number of the segmented tool bits 2 on each brazing diamond saw blade is set to be 24-36 according to a specific use scene. Because the material of the workpiece to be cut is generally casting material, most of the material has certain brittleness, and part of the material difficult to machine has certain hardness and toughness, the length of the tool bit of the sectional type tool bit 2 is set to be 35 mm-40 mm, which is more suitable. If the length of the cutter head is too large, poor heat dissipation is easily caused; too small a tip length, however, is likely to cause impact, leading to premature failure of the diamond 4 at the segment tip 2.

As shown in fig. 2, the slot 3 of the brazing diamond saw blade of the present invention is shaped like a key, the notch of the slot 3 is not provided with an oblique angle, etc., and the diamond 4 is welded to the edge of the notch, so that the continuity of the entire brazing diamond saw blade is better, the vibration is relatively lower when cutting cast iron or cast steel material, the segment type cutter head 2 is less likely to be adhered, and the cast material such as cast iron or cast steel can be cut more professionally. Meanwhile, the design also avoids the problems that the arrangement of the bevel angle is favorable for extruding and discharging the brittle materials, and is more favorable for cutting hard and brittle materials such as stone and the like but is not suitable for cutting metal materials.

In the brazing diamond saw blade provided by the invention, 3-4 through holes 22 are uniformly formed in each sectional type tool bit 2, and the through holes 22 distributed on the sectional type tool bits 2 mainly play a role in heat dissipation and chip removal, which is very important in the cutting processing of casting materials such as cast iron, cast steel and the like, and the heat and chips are timely discharged, so that the frictional wear of the diamond 4 can be effectively avoided. The size range of the through hole 22 is set to be 3-4 mm, so that effective heat dissipation can be guaranteed, and meanwhile, the saw blade matrix 1 can keep certain strength.

The through hole 22 is tangent to the arc boundary of the diamond cloth region 21, and preferably, the diamond 4 in the diamond cloth region 21 is located at the top end of the through hole 22 and is directly tangent to the through hole 22. This is because, in the diamond distribution region 21, for the saw blade base 1 portion on which the diamond 4 is arranged, the post-welding tensile strength is different from that of the saw blade base 1 region on which the diamond 4 is not welded; the area with the through hole 22 has lower overall strength than the area without the through hole 22, and if the diamond 4 is welded, the strength of the edge area of the diamond 4 is lower, which may cause the segment type cutting head 2 to tear; thus, the diamond 4 is arranged as much as possible above the top end of the through hole 22. The "tip" is herein positioned with reference to a direction connecting the through hole 22 and the center of the saw blade body 1 and away from the center.

The brazing diamond saw blade provided by the invention has the advantages that the outer diameter of a saw blade matrix 1 is 300-500 mm, the thickness is 2.5-3 mm, and the material is 50a steel or the steel grade with comprehensive performance higher than 50a steel. Under the same rotating speed, the larger the brazing diamond saw blade (namely the larger the outer diameter of the saw blade matrix 1), the higher the cutting line speed is, the larger the torque of the outer edge of the saw blade is, and the cutting performance is high; however, an excessively large saw blade is not favorable for cutting different positions of the special-shaped piece, and size and position interference is easy to occur. Therefore, 300mm to 500mm is a preferable size for the size of the workpiece, and 400mm is a preferable outer diameter size according to the existing grinding and cutting equipment and system. Meanwhile, the saw blade matrix 1 can not be too thick, otherwise, the material removal amount is large during cutting, the heat is more, and the burning and the cutting blockage are more likely to occur; and the saw blade matrix 1 is thin, the cutting strength is not enough, and the cutting precision and quality are influenced. Therefore, according to the ratio range of the outer diameter to the thickness of the blade body 1 and the cutting load, a blade having a thickness of 2.5mm to 3.0mm is selected as an appropriate range, and 2.7mm is the most preferable range. The brazing diamond saw blade performs cutting motion during application, and the cutting stability is a very critical cutting requirement. In order to ensure stable cutting, the strength of the saw blade matrix 1 is required to be higher before vacuum welding and the dimensional accuracy of the matrix is ensured, and the higher matrix strength and the higher matrix accuracy can still be maintained after high-temperature welding. According to the optimization of cutting materials and cutting conditions, the selection of 50a steel or other steel types with higher comprehensive performance is more suitable.

The blade body 1 has a blade hole 11 at the center thereof for holding the brazing diamond blade when the brazing diamond blade is used.

Because the diamond saw blade is easy to adhere and graphitize when the cast steel workpiece is polished, when the brazing diamond saw blade provided by the invention is applied to a robot for polishing and cutting casting materials, the influence of the motion parameters and the processing working conditions of the robot on the grinding performance of the brazing diamond saw blade needs to be particularly noticed. Based on the brazing diamond saw blade, the process method for cutting casting materials comprises the following aspects:

first, the saw blade is fixed. Generally, the brazed diamond saw blade is clamped and fixed by a main shaft and a flange of a cutting robot.

Then the working parameter control and the grinding cooling spraying control are carried out.

Specifically, on one hand, the rotating speed of a main shaft of the cutting robot is regulated and controlled to be 2000 rpm-4500 rpm, and the rotating speed is adjustable so as to adapt to the requirements of materials of different workpieces to be cut and different processing parameters; the power of the spindle motor is not lower than 4kW, and a large torque is provided to ensure the grinding efficiency.

It should be noted that, during the cutting process, the feed rate of the cutter is adjustable to adapt to the cutting rates of different processing parts; and in the feeding process, a pause can be set to reduce the cutting load and the generation of cutting heat. For example, during the cutting, the feeding speed is 2mm/s, after 5s, the feeding is stopped for 3s, and then the feeding is continued.

On the other hand, the cutting fluid or the oil mist is cooled by high pressure cutting fluid or oil mist, and the pressure of the cooling fluid is controlled to be more than 0.4 MPa. The grinding and cooling are the key for the stable operation of the saw blade, and the diamond 4 can be ensured not to be abraded by friction and graphitized. In order to achieve efficiency, the cooling liquid needs to effectively enter the cutting area, and the pressure value of the cooling liquid is larger to enable the sprayed cooling liquid to be larger than the linear cutting speed and enable the cooling liquid to really reach the cutting area due to the fact that the speed of the cutting line reaches over 45 m/s.

Specifically, as shown in fig. 3, two ejection regions, i.e., a main ejection region 210 and a sub ejection region 220, are provided to eject the coolant. Wherein, the main injection area 210 is a cutting part where the brazing diamond saw blade 100 and the workpiece 300 to be cut are contacted, and is to rapidly cool the brazing diamond saw blade 100 along with the high-speed rotation of the cutting process; the secondary injection zone 220 is the front end of the primary injection zone 210 and is located opposite the brazed diamond saw blade 100 no more than the primary injection zone 210, which ensures that the temperature of the abrasive particles entering the machining zone is low.

Obviously, the number and pressure of the spray heads can be increased to maximize the cooling effect when conditions permit. The position of the nozzle is required to be relatively fixed when the nozzle moves along with the cutting tool, namely, the relative position of the cooling point is not changed when the brazing diamond saw blade 100 is displaced.

The brazing diamond of the present invention and its particular application in cutting cast materials will be demonstrated by specific examples below.

Example 1

In this example, a brazed diamond saw blade was used to cut risers into HT-250 cast iron parts, the dimensions of the risers being around 25mm by 35 mm.

Specifically, in the brazed diamond saw blade, the diamond grain size of the diamond brazed to the diamond cloth region was 25/30 mesh, and the distribution density was 80 particles/cm²The diamond is of grade Yangyin Juxin SMD 40.

The saw blade is made of 50A steel, wherein the aperture of a saw blade hole is 32mm, the outer diameter of a saw blade matrix is 500mm, and the thickness of the saw blade matrix is 3 mm; the edge of the saw blade base body is divided into 42 sectional type cutter heads, each sectional type cutter head is provided with 3 through holes with the diameter of 4mm, and the width of a slot between the sectional type cutter heads is 3mm, and the depth of the slot between the sectional type cutter heads is 12 mm.

When the brazing diamond saw blade is used for cutting HT-250 cast iron, the cutting speed is controlled to be 3500rpm, the rated power of a spindle motor is 15kW, stable feeding is realized, and meanwhile, cooling liquid with the pressure of 0.5MPa is added to a cutting area for cooling.

The workpiece is cut by the process, the highest cutting speed of 2.2s can be achieved, the cut burn is almost avoided after the workpiece is stabilized within 2.8 s-5 s, and the workpiece can be cut by more than 12000 pieces at the highest; compared with the commercially available resin cutting blade under the same working condition, the brazing diamond saw blade has the advantages that the cutting efficiency is improved by 35 percent, and the overall cutting comprehensive cost is reduced by more than 20 percent.

Example 2

In this example, a brazed diamond saw blade was used to cut the high nickel cast iron D3.5 turbine shell. When the brazing diamond saw blade is used for cutting D3.5 turbine shell high-nickel cast iron, four risers are required to be cut, and each riser is in a cylindrical shape with the diameter of about 35 mm.

In the brazing diamond saw blade, the particle size of diamond brazed in the diamond cloth area is 30/35 meshes, and the distribution density is 90 particles/cm²The diamond is of grade Yangyin Juxin SMD 45.

The saw blade is made of 50A steel, wherein the aperture of a saw blade hole is 80mm, the outer diameter of a saw blade matrix is 400mm, and the thickness of the saw blade matrix is 2.7 mm; the edge of the saw blade base body is divided into 32 sectional type cutter heads, each sectional type cutter head is provided with 3 through holes with the diameter of 3.5mm, and the width of a slot between the sectional type cutter heads is 3mm, and the depth of the slot between the sectional type cutter heads is 12 mm.

When the brazing diamond saw blade is used for cutting D3.5 turbine shell high-nickel cast iron, the cutting speed is controlled to be 3500rpm, the rated power of a spindle motor is 4kW, stable feeding is realized, and meanwhile, a cooling liquid with the pressure of 0.6MPa is added to a cutting area and an axial symmetric area of a saw blade cutting area for cooling.

The workpiece is cut by the process, the highest cutting beat of 120s can be achieved, the cut is stable within 140 s-170 s, the burn of the cut is small, and 322 workpieces can be cut at the highest level; compared with the commercially available resin cutting blade with the same working condition, the brazing diamond saw blade has the advantages that the cutting efficiency is improved by 40 percent, and the overall cutting comprehensive cost is reduced by more than 30 percent.

Example 3

In this example, a brazed diamond saw blade was used to cut a cast stainless steel turbine shell of 1.4849 stainless steel material. When the brazing diamond saw blade is used for cutting a cast stainless steel turbine shell, six risers are required to be cut, and each riser is in a cylindrical shape with the diameter of about 35 mm.

In the brazing diamond saw blade, the particle size of diamond brazed in the diamond cloth area is 25/35 meshes, and the distribution density is 95 particles/cm²The diamond is of grade Yangyin Juxin SMD 45.

The saw blade is made of 50A steel, wherein the aperture of a saw blade hole is 80mm, the outer diameter of a saw blade matrix is 350mm, and the thickness of the saw blade matrix is 2.6 mm; the edge of the saw blade base body is divided into 32 sectional type cutter heads, each sectional type cutter head is provided with 3 through holes with the diameter of 3.5mm, and the width of a slot between the sectional type cutter heads is 2.5mm, and the depth of the slot between the sectional type cutter heads is 16 mm.

When the brazing diamond saw blade is used for cutting D3.5 turbine shell high-nickel cast iron, the cutting rotating speed is controlled to be 2650rpm, the rated power of a spindle motor is 4kW, when a cutting dead head is fed, after two thirds of the width of the dead head is stably fed, the cutting is stopped for 1s, then the cutting is continued, and meanwhile, a cooling liquid with the pressure of 0.6MPa is added to the cutting area and the axial symmetric area of the saw blade cutting area for cooling.

The workpiece is cut by the process, the highest cutting beat can reach 220s, the cut burn is small after the workpiece is stabilized within 250 s-300 s, and 170 workpieces can be cut at the highest; compared with the commercially available resin cutting blade with the same working condition, the brazing diamond saw blade has the advantages that the cutting efficiency is improved by 50 percent, and the overall cutting comprehensive cost is reduced by more than 30 percent.

While the invention has been shown and described with reference to certain embodiments, those skilled in the art will understand that: various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents.

Claims (10)

1. The brazing diamond saw blade for cutting cast iron or cast steel is characterized by comprising a saw blade substrate, wherein a plurality of sectional type tool bits formed by interval of slots are arranged at the edge of the saw blade substrate, a diamond cloth area is arranged on the outer edge of each sectional type tool bit, diamonds are brazed in the diamond cloth area, and the sections are divided into two sectionsThe section type cutter head is provided with a through hole; wherein the width of the slot is not more than 3mm, and the depth is 12 mm-30 mm; the granularity of the diamond is 20-40 meshes, the average static compressive strength is not lower than 350N, and the cold impact breakage rate is not lower than 82%; and the diamond distribution density of the diamond distribution area is 55 particles/cm²About 120 particles/cm²。

2. The brazed diamond saw blade of claim 1, wherein the slot has a width of 1.8mm to 2.5mm and a depth of 15mm to 20 mm; the granularity of the diamond is 25-35 meshes; and the diamond distribution density of the diamond distribution area is 70 particles/cm²95 particles/cm²。

3. The brazed diamond saw blade of claim 2, wherein the slot is key-shaped.

4. The brazed diamond saw blade as set forth in any one of claims 1 to 3, wherein the through-hole is tangent to the arc-shaped boundary of the diamond cloth region.

5. The brazed diamond saw blade of claim 4, wherein the diamonds in the diamond cloth region are located at the top end of the through hole and tangent to the through hole.

6. The brazed diamond saw blade of claim 4, wherein the diamond cloth regions are located on opposite side faces of the segment tip and a tip edge face of the segment tip; wherein the cloth width of the diamond cloth area on the side surface is 3-5 mm.

7. The brazed diamond saw blade of claim 4, wherein in the diamond cloth region, the average depth of embedding of the braze is 30-50% of the grain size of the diamond.

8. The brazed diamond saw blade of claim 4, wherein the number of segment segments is 24-36; 3-4 through holes are uniformly formed in each sectional type cutter head; wherein the aperture of the through hole is 3 mm-4 mm.

9. The brazing diamond saw blade according to claim 4, wherein the saw blade base body has an outer diameter of 300mm to 500mm, a thickness of 2.5mm to 3mm, and is made of 50a steel or a steel grade having a combination property higher than 50a steel; the length of the sectional type cutter head is 35-40 mm.

10. A process for cutting cast iron or steel based on a brazed diamond saw blade according to any one of claims 1 to 9, comprising:

a saw blade fixing step: clamping and fixing the brazing diamond saw blade of any one of claims 1 to 9 by using a main shaft and a flange of a cutting robot;

and working parameter control: regulating and controlling the rotating speed of a main shaft of the cutting robot to be 2000 rpm-4500 rpm, and the power of a main shaft motor to be not lower than 4 kW;

grinding, cooling and spraying: controlling the pressure of the cooling liquid to be more than 0.4MPa, and respectively spraying the cooling liquid to the main spraying area and the auxiliary spraying area; the main spraying area is a cutting part of the brazing diamond saw blade contacted with a workpiece to be cut, and the auxiliary spraying area is the front end of the main spraying area and is not more than the main spraying area and is positioned opposite to the brazing diamond saw blade;

and starting the cutting robot under the conditions of the working parameter control step and the grinding, cooling and spraying step, and cutting the workpiece to be cut by adopting the brazing diamond saw blade.

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