钎焊金刚石磨削石材过程中磨粒磨损状态研究

通过数字视频采集系统跟踪观察钎焊金刚石砂轮磨削过程中磨粒表面形貌变化.研究了钎焊金刚石砂轮在磨削花岗石材料过程中,金刚石磨粒的出刃高度和磨损状态的变化规律.结果表明,钎焊金刚石工具在加工过程中,钎焊金刚石磨粒可分为六种磨损状态:完整晶形、微观破碎、宏观破碎、磨平、折平和脱落.磨粒磨损路径主要是以完整→微观破碎→宏观破碎→脱落的方式进行.金刚石磨粒在磨损过程中,可分为初期磨损、正常磨损和剧烈磨损三个阶段.     

新连接方式金刚石磨损特征的试验研究

以端面磨盘形式为载体,通过恒压磨耗试验研究了采用液体合金方式连接的金刚石的磨损特征。结果表明,新连接方式金刚石使用过程的磨损形态主要有完整、磨平、微观破碎、宏观破碎和折断五大类,与钎焊金刚石的磨损特征基本一致。磨耗过程中没有出现磨粒脱落现象,说明新连接方式工具的结合剂对磨粒具有很强的把持力。但与钎焊工具相同,磨粒折断是其最为致命的失效形式。     

切割混凝土的金刚石锯片研究

本文通过对切割混凝土锯片磨损的理论分析，进行了分段式节块锯片、斜槽式节块锯片、三明治节块锯片、涡轮齿式节块锯片，三孔式节块锯片与传统标准扇形节块锯片切割对比试验研究，结果表明，上述特殊形状节块锯片利于冷却和排粉，切割效率和使用寿命优于传统标准扇形节块锯片。还进行了不同金刚石配方试验。认为，采用粗细粒度金刚石混合配方，结合采用利于冷却排粉的几何结构节块，可以显著提高混凝土切割锯片的切割效率和使用寿命。     

粉末冶金烧结热等静压氮化金刚石节块

本文引用粉末冶金强调保护气氛烧结。提出了金刚石节块的失效及选材，讨论了氮化物体中性及自由原子结合作用力烧结、氮化金刚石节块。由于节块选材渗Ｓｉ３Ｎ４代替部分金刚石（浓度）及配用铁基（以Ｆｅ代Ｃｏ）结合剂氮化“钢结”。大大降低成本。该节块耐磨稳定，性能良好，在石材切割过程中，节块Ｓｉ３Ｎ４随着金刚石同等磨损自励共济，且Ｓｉ３Ｎ４自带润滑作用，让载机动力减轻负荷加快进给及减弱磨削工作噪声，从而加工好的     

两种合金化铜基钎料真空钎焊金刚石

采用机械合金化CuSn/TiH_2粉末和气雾化Cu-Sn-Ti钎料粉末对金刚石的进行真空钎焊实验,从金刚石钎焊形貌、界面生成物成分、钎料与基体结合情况、金刚石磨损形态等对比分析了两者的钎焊性能。研究表明:当钎焊温度为920℃,保温时间为10 min时,二者均能实现金刚石的高强度把持;气雾化Cu-Sn-Ti钎料在金刚石界面生成一层连续且致密的TiC层,而机械合金化CuSn/TiH_2粉末生成的TiC层相对较薄;两种钎料真空钎焊金刚石的钎焊性能较好,没有出现热刻蚀现象;真空钎焊金刚石磨粒在切削过程中主要经历了小块破碎、大块破碎以及磨平等正常磨损阶段;机械合金化Cu-Sn/TiH_2粉末钎焊的金刚石磨钝后出现了少数磨粒脱落的情况,但其脱落不会对磨具的整体切削性能产生影响,且其粉末制备成本低,在金刚石钎焊工艺中可考虑采用。     

金刚石圆锯片节块几何形状对磨损机理的影响

本文对目前石材加工领域广泛使用的具有几种典型节块结构的金刚石圆锯片的磨损机理进行了一些分析，讨论了节块几何形状和排列方式对锯片磨损的影响程度，并比较了从外观结构邮发制造中凹与单纯从配方的角度制造中凹的优缺点，最后从切削加工的角度对改进金刚石石圆锯质量提出了一些建议。     

金刚石的磨损形态对工具切割性能的影响

通过对不同金刚石锯片的切性能测试和磨损表面形貌观察，分析了工具中金刚石颗粒的磨损形态与工具胎体的磨损性能之间的关系及其对工具切割性能的影响，指出工具中磨平或抛光的金刚石对工具的切割性能不利，而新出刃和微破碎金刚石颗粒的增多，有利于提高工具的切割性能。     

陶瓷磨削中新型多孔金属结合剂金刚石砂轮磨损特征研究

在磨削Al2O3工程陶瓷材料过程中,利用三维视频显微镜跟踪观察了新型多孔金属结合剂金刚石砂轮,金刚石的磨损过程以及砂轮表面形貌的变化。分析了新型砂轮中金刚石磨损的主要形式及原因,砂轮工作表面的状态变化特征。试验结果表明：新型多孔金属结合剂金刚石砂轮在加工过程中,金刚石的磨损形式包括磨耗磨损,破碎及脱落等磨损过程,其中以磨耗磨损为主;同时,随着结合剂的不断磨除,砂轮深层磨料能够不断出露,取代表面钝化失效、脱落的金刚石,且砂轮表面孔隙结构,随磨损过程呈交替更迭变化,砂轮具有较好的自锐性。     

电镀金刚石线锯切割光伏多晶硅的表面特性与锯丝磨损分析

电镀金刚石线锯切割的光伏多晶硅切片表面特性,影响其断裂强度和后续的制绒工艺;为探究线锯锯切工艺参数对多晶硅切片表面特性的影响规律,揭示电镀金刚石锯丝的磨损机理,开展了光伏多晶硅的电镀金刚石线锯切片试验。研究结果表明:锯切的多晶硅表面存在由金刚石磨粒的塑性剪切、微切削去除形成的塑性浅划痕与较深的沟槽,及材料脆性去除留下的表面破碎微凹坑;切片表面材料的塑性去除和脆性去除相对比例随工艺参数组合变化而变化,增大晶片进给速度,降低走丝速度,切片表面粗糙度增大,表面形貌逐渐由塑性沟槽为主转变为以破碎微凹坑为主;使用表面镀镍(金属化)的金刚石颗粒制备的电镀金刚石锯丝的磨损形态在稳定阶段主要是磨粒磨平,使用后期主要是磨粒脱落和镀层磨损。      

玻璃磨削中电镀金刚石工具的磨损

以镍钴合金为结合剂制备了电镀金刚石工具,对平板玻璃进行了磨边实验,用扫描电子显微镜观察电镀金刚石工具的磨损状态。在玻璃加工过程中,金刚石工具的磨损分为金刚石磨损和结合剂磨损两种情况。金刚石的磨损形式包括：破碎,磨平以及脱落。结合剂的磨损为：在金刚石颗粒的前方形成较深的凹坑,两侧形成较浅的凹坑,金刚石磨粒的后面则形成结合剂的隆起。随着磨削过程的进行,工具的结合剂逐渐被磨除,玻璃磨屑的颜色也相应的由白色向黑色变化。研究结果表明,制备电镀金刚石工具时,电镀结合剂与金刚石磨粒磨损应保持同步,充分发挥金刚石工具的切削作用。     

金刚石框架锯锯切研究（Ⅴ）—金刚石结块磨损特征

在对金刚石框架锯锯切加工动力学，锯切破碎机理模型和金刚石框架锯锯切加工石材时的切削力研究的基础上，通过金刚石锯条锯切石材的实验，测量并分析了金刚石结块磨损特征及其分类，金刚石结块磨损机理，金刚石结块磨损与加工时间，进给速度，石材种类，金刚石结块性能和锯条张紧力等因素的关系，提出了加工参数和金刚石结块的优选原则，研究结果为系统开发和改进金刚石工具提供了一个良好的基础，基于 这些结果，可改进结合剂，金刚石质量，金刚石浓度，金刚石粒度，结块尺寸和结块间隔。     

The effect of operational parameters on diamond tools of frame sawing system: Wear characteristics and optimization in stone processing

A series of sawing experiments was carried out to investigate the effect of operational parameters on the wear characteristics of diamond segment. And the wear mechanism of diamond segment was studied through micro-morphology. The analysis presented that the wear mechanisms of segment metal matrix are mainly attributed to abrasive wear and erosion wear, the wear mechanism of diamond particles mainly includes cleavage fracture caused by the impact load and abrasion caused by scratching. The effect of sawing parameters on the wear rate of segment matrix is consistent with that of diamond particles. The wear resistance of segment matrix increases with the increase of the proportion of diamond particles with micro-fractured and complete crystalline shape, and decreases with the increase of the proportion of diamond particles with macro-fractured and pulled-out. Furthermore, the predicted model was established to evaluate the segment wear per unit by using Design Expert software, and the optimum sawing parameters obtained as a result of the optimization was investigated to provide some guidance for the processing of the enterprise.     

Comparison of wear performance of diamond tools in frame sawing with different trajectories

In this study, experiments were performed to explore the wear performance of diamond tools with different sawing trajectories in stone processing. The wear morphologies of the diamond segments were analyzed by an optical microscope and scanning electron microscopy. The wear behavior of the diamond segment was investigated comprehensively from the aspects of the wear morphology of matrix and diamond, the remaining height of segments and the height of protrusion of diamond particles. The results indicated that matrix tails are developed behind diamond particles in impacted frame saws guided by the specific eccentric hinge mechanisms. The sawblades can be lifted and cut stone at the maximum horizontal velocity, create many new cutting edges, so that the diamond particles with cutting ability in impacted frame saws are higher than that of the horizontal frame saw. In addition, the hinge mechanisms of impacted frame saws placed in the same direction are conducive to the uniformity of segment wear compared with the hinge mechanisms placed symmetrically. Impact wear is the main wear mechanism of the diamond particles in impacted frame saws, while impact load also accelerates the fracture of diamond particles. Accordingly, the difference of protrusion height between three kinds of frame saws is not particularly large.     

Investigation and improvement of wear nonuniformity of diamond tools in sawing granite

Sawing experiments were accomplished to discuss the wear characteristics at different parts of diamond tools in the process of sawing granite in this paper. Optical microscopy, scanning electron microscopy and 3D laser microscope were main detection means for the morphology of diamond tools. Synthetic investigation on the abrasion performance of segments was developed from aspects of the wear appearance of diamond particle and metal bond, the particle protrusion height and the residual height of segments. The results indicated that smaller residual height and larger proportion of macro-fractured and pull out crystal were exhibited at the front end of traditional diamond segment compared with the rear end. Morphology characteristics of diamond tools demonstrated different abrasion mechanism, flush erosion and cavitation was the main wear mechanism for the front end, while abrasive wear was the main wear mechanism for the rear end. Maximum undeformed chip thickness per diamond particle for the front end was larger than that of the rear end due to the existence of slot, the same was true for the load of single diamond particle. By reasonably matching of diamond particles and matrix bond, the abnormal failure efficiency of the diamond particles at the front of the segment was effectively reduced and the wear uniformity of the saw tooth surface was greatly improved. Suggestions on the design of diamond tools and test verification were put forward in the end.     

金刚石圆锯片节块几何形状对磨损机理的影响

本文对目前石材加工领域广泛使用的具有几种典型节块结构的金刚石圆锯片的磨损机理进行了一些分析。讨论了节块几何形状和排列方式对锯片磨损的影响程度,并比较了从外观结构出发制造中凹与单纯从配方的角度制造中凹的优缺点。最后从切削加工的角度对改进金刚石圆锯片的质量提出了一些建议。     

Effects of diamond grain characteristics on sawblade wear

One-segmented diamond sawblades containing diamond with varying degrees of etch pits were manufactured to study the wear behaviour of diamond grains during the sawing of granite. The worn surfaces of the diamond segments were analysed by a scanning electron microscope (SEM), and the forces acting on the tool and the wear performance were measured. The results showed that a sawblade containing diamond with a small number of pits during sawing displays predominantly microfractured worn particles on the working segment surface, a lower sawing force, and a better wear performance. When a tool containing a greater number of extensive pits on the diamond grains is used, a higher proportion of macrofracture occurred and wear flats appeared on the worn diamonds. In addition, the sawing forces are relatively higher and the blade performance is poorer.     

金刚石框架锯锯切研究(Ⅵ)--在实验机上模拟框架锯锯切过程

测定金刚石框架锯锯切切削力，金刚石结块磨损和锯条变形等是十分重要也是非常困难的。在前面对锯切运动，锯切机理，锯切切削力和金刚石结块磨损研究的基础上，介绍了一种在实验室里用小型框架锯切实验机模拟框架锯锯切过程的实验方法，比较了用单锯条三节块和单锯条单结块锯切石材的实验结果，优选了结块分布间距，与金刚石框架锯锯切加工实验结果的比较表明，在实验机上用单锯条三节块锯切石材时，测量得到的处于中间的金刚石结块的切削性能，可以较好地反映实际加工中金刚石结块的切削状态，利用这一结果，可快速地通过简单的实验，评价金刚石锯条在实际加工中的切削力和金刚石结块磨损特性，其误差在20%以内。     

结合剂氯含量对金刚石锯片性能的影响

采用氮/氧自动分析仪及SEM、XRD等手段分析了结合剂粉末中氧含量及其对锯片性能的影响.结果发现在烧结过程中,含氧量高的结合剂对金刚石形成了强烈的侵蚀,金刚石表面形成了许多凹坑,最终导致在切削过程中金刚石发生整体破碎的比例大幅度增加,工具的寿命和效率急剧下降.     

金刚石框架锯锯切研究(VII)━计算机模拟框架锯锯切过程基础

基于框架锯锯切加工运动学分析、单颗粒和单结块切削力试验结果 ,讨论了采用计算机模拟框架锯锯切过程中所需的运动学、金刚石结块磨损和金刚石颗粒切削力模型 ,以及模拟过程图。采用简化方法计算了金刚石结块表面的理论金刚石颗粒数 ;结合对金刚石结块磨损的研究结果 ,用MontoCarlo方法生成了结块表面的金刚石颗粒的出刃高度、分布位置和磨损形态 ,生成了数字化的金刚石锯条 ,为计算机模拟框架锯锯切加工过程 ,提供了基础数据。