WO2015021593A1 - Diamond bead string, method for manufacturing same and wire saw without matrix support layer - Google Patents
Diamond bead string, method for manufacturing same and wire saw without matrix support layer Download PDFInfo
- Publication number
- WO2015021593A1 WO2015021593A1 PCT/CN2013/081355 CN2013081355W WO2015021593A1 WO 2015021593 A1 WO2015021593 A1 WO 2015021593A1 CN 2013081355 W CN2013081355 W CN 2013081355W WO 2015021593 A1 WO2015021593 A1 WO 2015021593A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- diamond
- bead
- beads
- bead string
- wire saw
- Prior art date
Links
- 239000010432 diamond Substances 0.000 title claims abstract description 181
- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 180
- 239000011324 bead Substances 0.000 title claims abstract description 157
- 238000000034 method Methods 0.000 title claims abstract description 54
- 239000011159 matrix material Substances 0.000 title claims abstract description 13
- 238000004519 manufacturing process Methods 0.000 title abstract description 17
- 229910052751 metal Inorganic materials 0.000 claims abstract description 63
- 239000002184 metal Substances 0.000 claims abstract description 60
- 239000000843 powder Substances 0.000 claims abstract description 47
- 238000005245 sintering Methods 0.000 claims abstract description 38
- 238000001746 injection moulding Methods 0.000 claims abstract description 28
- 239000011230 binding agent Substances 0.000 claims abstract description 24
- 239000000463 material Substances 0.000 claims abstract description 18
- 238000005238 degreasing Methods 0.000 claims abstract description 17
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 11
- 238000000465 moulding Methods 0.000 claims abstract description 11
- 239000010959 steel Substances 0.000 claims abstract description 11
- 239000000203 mixture Substances 0.000 claims description 37
- 239000002245 particle Substances 0.000 claims description 12
- 229920001971 elastomer Polymers 0.000 claims description 11
- 229910052710 silicon Inorganic materials 0.000 claims description 9
- 229910045601 alloy Inorganic materials 0.000 claims description 8
- 239000000956 alloy Substances 0.000 claims description 8
- 229910052796 boron Inorganic materials 0.000 claims description 8
- 238000003825 pressing Methods 0.000 claims description 8
- 229910052719 titanium Inorganic materials 0.000 claims description 8
- 239000010936 titanium Substances 0.000 claims description 8
- -1 Polyethylene Polymers 0.000 claims description 7
- 229910052804 chromium Inorganic materials 0.000 claims description 7
- 239000011651 chromium Substances 0.000 claims description 7
- 239000010949 copper Substances 0.000 claims description 7
- 239000012188 paraffin wax Substances 0.000 claims description 7
- 229910052721 tungsten Inorganic materials 0.000 claims description 7
- 229910052802 copper Inorganic materials 0.000 claims description 6
- 229910052698 phosphorus Inorganic materials 0.000 claims description 6
- 238000002360 preparation method Methods 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 239000004698 Polyethylene Substances 0.000 claims description 5
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 5
- 229910052799 carbon Inorganic materials 0.000 claims description 5
- 229920000573 polyethylene Polymers 0.000 claims description 5
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 4
- 235000021355 Stearic acid Nutrition 0.000 claims description 4
- 229910052739 hydrogen Inorganic materials 0.000 claims description 4
- 239000001257 hydrogen Substances 0.000 claims description 4
- 229910052742 iron Inorganic materials 0.000 claims description 4
- 229910052750 molybdenum Inorganic materials 0.000 claims description 4
- 229910052759 nickel Inorganic materials 0.000 claims description 4
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 claims description 4
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 claims description 4
- 239000008117 stearic acid Substances 0.000 claims description 4
- 229910052718 tin Inorganic materials 0.000 claims description 4
- 229910052580 B4C Inorganic materials 0.000 claims description 3
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 3
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 3
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052748 manganese Inorganic materials 0.000 claims description 3
- 239000011733 molybdenum Substances 0.000 claims description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 3
- 239000010703 silicon Substances 0.000 claims description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 3
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 3
- 239000010937 tungsten Substances 0.000 claims description 3
- 239000000314 lubricant Substances 0.000 claims description 2
- 150000002739 metals Chemical class 0.000 claims description 2
- 239000004033 plastic Substances 0.000 claims description 2
- 229920003023 plastic Polymers 0.000 claims description 2
- 239000004014 plasticizer Substances 0.000 claims description 2
- 229920005992 thermoplastic resin Polymers 0.000 claims description 2
- 239000011135 tin Substances 0.000 claims description 2
- 229910052582 BN Inorganic materials 0.000 claims 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims 1
- 238000005520 cutting process Methods 0.000 abstract description 13
- 239000004575 stone Substances 0.000 abstract description 9
- 238000002156 mixing Methods 0.000 abstract description 8
- 230000009286 beneficial effect Effects 0.000 abstract 1
- 238000007731 hot pressing Methods 0.000 abstract 1
- 238000005470 impregnation Methods 0.000 abstract 1
- 239000000047 product Substances 0.000 description 29
- 239000010410 layer Substances 0.000 description 27
- 239000000758 substrate Substances 0.000 description 11
- 239000002994 raw material Substances 0.000 description 8
- 229920001169 thermoplastic Polymers 0.000 description 6
- 239000004416 thermosoftening plastic Substances 0.000 description 6
- 238000013461 design Methods 0.000 description 5
- 238000002347 injection Methods 0.000 description 5
- 239000007924 injection Substances 0.000 description 5
- 239000011148 porous material Substances 0.000 description 5
- 239000000243 solution Substances 0.000 description 5
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- 238000009472 formulation Methods 0.000 description 3
- 239000010438 granite Substances 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910052810 boron oxide Inorganic materials 0.000 description 2
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 230000008595 infiltration Effects 0.000 description 2
- 238000001764 infiltration Methods 0.000 description 2
- 239000004579 marble Substances 0.000 description 2
- 239000012768 molten material Substances 0.000 description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 239000004597 plastic additive Substances 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- 229930182556 Polyacetal Natural products 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- NEIHULKJZQTQKJ-UHFFFAOYSA-N [Cu].[Ag] Chemical compound [Cu].[Ag] NEIHULKJZQTQKJ-UHFFFAOYSA-N 0.000 description 1
- 239000003125 aqueous solvent Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 150000002085 enols Chemical class 0.000 description 1
- BFMKFCLXZSUVPI-UHFFFAOYSA-N ethyl but-3-enoate Chemical compound CCOC(=O)CC=C BFMKFCLXZSUVPI-UHFFFAOYSA-N 0.000 description 1
- 239000006023 eutectic alloy Substances 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 150000004676 glycans Chemical class 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 238000001513 hot isostatic pressing Methods 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 238000011031 large-scale manufacturing process Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000010310 metallurgical process Methods 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000009740 moulding (composite fabrication) Methods 0.000 description 1
- 201000009240 nasopharyngitis Diseases 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- 150000002843 nonmetals Chemical class 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920006324 polyoxymethylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920001282 polysaccharide Polymers 0.000 description 1
- 239000005017 polysaccharide Substances 0.000 description 1
- 229920000131 polyvinylidene Polymers 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000007779 soft material Substances 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
- B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
- B28D1/08—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing with saw-blades of endless cutter-type, e.g. chain saws, i.e. saw chains, strap saws
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D61/00—Tools for sawing machines or sawing devices; Clamping devices for these tools
- B23D61/18—Sawing tools of special type, e.g. wire saw strands, saw blades or saw wire equipped with diamonds or other abrasive particles in selected individual positions
- B23D61/185—Saw wires; Saw cables; Twisted saw strips
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D65/00—Making tools for sawing machines or sawing devices for use in cutting any kind of material
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/005—Article surface comprising protrusions
Definitions
- the invention discloses a diamond bead, a preparation method and a diamond wire saw which does not require a base supporting layer, and belongs to the technical field of diamond tool components according to the International Patent Classification Table (IPC), in particular to a metal powder injection molding process (MIM) ) Production of diamond beads, which are important components of diamond wire saws or wire saws.
- IPC International Patent Classification Table
- MIM metal powder injection molding process
- the diamond wire saw is made up of a cylindrical diamond bead string on the wire rope, and each bead is fixed by a rubber spacer to form a complete diamond wire saw, wherein the cylindrical diamond bead is made up of a cylindrical base layer. A and the upper diamond-containing particle working layer B are formed, as shown in FIG. This is the general structure of diamond diamond beads.
- diamond wire saw has been promoted since 1970. Because its length can be adjusted for the size of the object to be cut, the bending is good, and it has strong applicability to the cutting environment, it is widely used in granite and marble mining and cutting. Shaped and curved stone products in stone processing plants, etc. In addition, diamond wire saws can also be used for the cutting of concrete columns and other buildings.
- the existing diamond wire saw outer diameter is ⁇ 7- ⁇ 11 mm, wherein the basic production process of diamond bead is as follows: First, the cylindrical bead substrate is prepared, the metal powder and the diamond are mixed well, and then loaded. Cold pressing on the metal cold stamping die, that is, cold pressing the working layer onto the bead substrate, or first cold pressing a working layer ring and then inserting on the base body to form a rough blank of similar shape, and then placing the cold pressed blank In the graphite mold, it is placed in a hot press to form a hot press. Another sintering process is to directly form a cold pressed blank into a hydrogen furnace for sintering.
- sintering is also performed by a hot isostatic pressing process.
- diamond is directly bonded to the surface of the substrate by electroplating and brazing processes to form diamond beads, but This product can only be used for the cutting of soft materials such as marble, otherwise it will have a short service life due to the single layer of diamond.
- the diamond bead production process is mainly a cold press forming sintering process, which usually involves placing the raw materials in a common cold press forming die, cold pressing the preforms, and then placing the preforms and the bead matrix together at a high temperature. Hot press (700-900 degrees) Sintered or sintered in a high temperature furnace. This traditional process is less efficient.
- the conventional process of producing diamond bead involves the formation of an annular matrix in the diamond bead, which is combined with a diamond-containing working layer to form a diamond bead.
- the purpose of the conventional diamond bead is to form a layer of the base body.
- the threaded groove can be processed on the inner wall of the base.
- the beaded rubber material is fixed beside the bead, which can be squeezed when the rubber material is formed.
- the length of the base layer is larger than that of the bead working layer, forming a stepped shape, and the stepped base body can also be embedded in the rubber material layer, so that the bead is not easily rotated and fails during the cutting process.
- the base body of about 1 mm can increase the outer diameter of the overall diamond wire saw, and the production cost is high.
- the outer diameter of the diamond wire saw increases, which increases the slit when cutting the stone, resulting in a great waste of stone material.
- the cost per square meter of diamond wire saw is higher than that of diamond circular saw or sand saw, so it cannot replace the use of diamond circular saw and sand saw;
- the universal small diameter wire saw has an outer diameter of 7.2 mm and a relatively wide slit, which also limits the cutting of its granite slab.
- the original metal powder injection molding process is the first First, the ultrafine metal prealloyed powder is uniformly mixed with a thermoplastic organic binder such as polyolefin, and after being granulated, it is placed in an injection molding machine and heated at about 150 ° C, and is molded into a cavity in which a product mold has been opened, and is solidified. forming. The organic binder in the solidified green compact is removed by a degreasing furnace or by chemical solution degreasing, and finally the blank is placed in a high temperature furnace and finally sintered.
- a thermoplastic organic binder such as polyolefin
- US Patent No. US2005271539 (A1), in the Chinese patent group CN 1714990, discloses a diamond element, such as an insert for a wire saw, prepared by a process comprising the steps of preparing a starting mixture of metal powder, plasticizing it with a specific plastic additive.
- the starting mixture, adding diamond particles, injection molding by MIM technology, removing plastic additives, and the prepared multilayer diamond-containing blanks are serially connected to the metal cylinder substrate, and then placed in a high temperature furnace for sintering, due to the sintering temperature of the finished product.
- the sintered product contains a lot of pores, so it is necessary to infiltrate the porous diamond beads into the eutectic alloy such as Cu/Ag or other low-temperature alloys for void penetration into the landfill.
- the production cost of this process is still high, because on the one hand, a lot of pores are formed on the sintered diamond element. Therefore, a process of infiltrating an alloy solution such as silver and copper must be added in the later stage, due to the price of silver-copper alloy.
- diamond bead is still a traditional design, that is, the diamond bead blank needs to be reloaded into the metal cylinder substrate and then sintered, so that The cost is increased and it is not possible to make small diameter multi-layer diamond beads. Even if a diamond bead containing a substrate of, for example, a diameter of 5 mm is formed, since it is worked on the substrate, it is not possible to have a sufficient thickness such as lmm or more, thereby affecting the service life of the cut stone. The addition of a metal circular cylinder base layer again increases the complexity of the process and thus increases the cost.
- the present invention provides a diamond bead and a preparation method thereof, that is, a diamond bead without a substrate support is designed, which is different from a single layer electroplated or brazed diamond bead, the substrateless support Diamond beading, also containing multiple layers of diamond, increasing the service life, and The secondary sintering is completed, and the final process of infiltrating an alloy solution such as silver or copper is not required.
- a method for preparing diamond bead comprises the following steps:
- the rough blank is placed in a vacuum furnace or a hydrogen furnace or a high-temperature furnace for one-time sintering to obtain a diamond beaded product.
- a vacuum furnace or a hydrogen furnace or a high-temperature furnace for one-time sintering to obtain a diamond beaded product.
- more pores are formed inside the product.
- we rationally design the formulation of metal powder We introduce a small amount of elements such as B, Si, P, etc., with parts of Co, Cr, Ni, W, WC, Mn, Fe, Cu, Sn, Mo or All form an alloy.
- elements such as B, Si, and P can lower the sintering temperature of the metal powder and eliminate voids during the sintering process.
- the above metals and non-metals can be made into pre-alloyed powders.
- One process for making a blank is to take a "pre-heat forming process”.
- the process involves hot-press molding of the mixture particles (including diamond, thermoplastic binder, metal powder) in a steel mold at a medium temperature hot press at a temperature of 10 ° C to 250 ° C, or at a temperature of 100. Pressing and forming a blank (blank) in a cavity of °C - 250 °C.
- the metal prealloyed powder is uniformly mixed with the diamond, and then an organic binder such as paraffin or polyethylene is added, and then mixed and granulated on the internal mixer, and the metal prealloyed powder can also be mixed on the medium temperature mixer.
- the particles having a diameter of about 3 mm are prepared, and then the particles are quantitatively loaded into a mold (see Fig. 7) and placed on a flat plate press at a temperature of 100-200 °C. Pressure. When the mold is hot pressed, the granular material is softened in a cavity of about 200 ° C, and the mold is pressed.
- the raw material on the funnel is extruded into the bottom cavity to form. Finally, the mold is cooled and demolded to obtain a cylindrical blank. The blank was placed in a degreasing furnace to remove the organic binder, and then sintered at 860 ° C in a high temperature furnace to form a final product.
- the diamond may also be other superhard materials such as cemented carbide, cubic boron oxide, boron carbide, diamond thick film, silicon carbide, aluminum oxide, and mixtures thereof.
- the diamond may also be surface-plated with titanium or coated with elements reactive with carbon, such as titanium, chromium, molybdenum, tungsten, boron, silicon, and mixtures thereof to enhance diamond in the metal matrix. The combination of strength, improve the life and efficiency of the working layer.
- the already-crushed cylindrical green compact containing diamond is degreased in a degreasing furnace and then placed in a vacuum furnace, or may be sintered in a high-temperature furnace containing a protective gas or a reducing gas.
- the sintered diamond bead blank has a sintering temperature of 700 ° C to 890 ° C.
- Another method of making a diamond bead blank is to directly form a unitary cylindrical bead using a metal powder injection molding process. In the process, the mixture particles (including diamond, thermoplastic binder, metal powder) are placed in an injection molding machine and injection molded to obtain a blank.
- the diamond product metal powder injection molding manufacturing process is as follows:
- the injection molding step is: after the mixture containing the organic binder is granulated, and then heated and melted in the injection molding machine cabinet, the molten material is injected into the designed product under the pressure of the screw of the injection molding machine. In the cavity of the shape, the mixture containing the organic binder is cooled and solidified due to the low temperature of the cavity.
- the molded blank can be obtained after demolding.
- the injection pressure can be 10--180 MPa.
- the difference between the pre-heat forming process and the metal powder injection molding process lies in the metal powder in the following steps. At the end, diamond and organic binder-mixing are somewhat different.
- the pre-heat forming process is that the raw material mixture is formed in a hot press, and the metal powder injection molding process (MIM) raw material mixture is formed in a hot press.
- MIM metal powder injection molding process
- the metal prealloyed powder we have adopted has a particle size of 0. 5-20 um in order to facilitate sintering.
- the metal powder component is B, P, Si, and some or all of them are composed of all or part of the following metal components: Co, Ni, Cu, Ti, Cr, Sn, Mo, Wc, W, Fe, Mn.
- the organic binder is composed of a thermoplastic resin, a plasticizer and a lubricant, and generally does not exceed 40% of the entire volume ratio.
- a thermoplastic resin e.g., polyethylene, paraffin, stearic acid and the like are used.
- Other organic binders such as polypropylene, ethyl vinyl acetate, polyethylene carbonate, polyvinylidene, paraffin, stearic acid, polyethyl b can also be used.
- the organic binder has a volume ratio of 25-50%, preferably 30-40%.
- the mixing step is to uniformly mix the diamond and the metal powder mixture with the organic binder, and the organic binder and the mixture material are integrated by blending and kneading, and are not separated from each other during the flow in the thermoplastic machine to improve The uniformity of the isotropic density of the article. In this way, the product can maintain its original shape during the sintering process, and the strength of each direction is uniform.
- Mixing can be carried out in a twin-screw extruder or twin-roll mixer, Z-vane or ⁇ -blade planetary mixer.
- the mixture containing the organic binder After the mixture containing the organic binder is granulated, it is heated and melted in the injection molding machine cabinet, and the molten material is injected into the injection mold of the designed product shape under the pressure of the screw of the injection molding machine.
- the injection mold cavity In the injection mold cavity, the main flow path of the mixed material flow, the split flow path, the product mold core, the product cavity, etc. are designed.
- the mixed material flows from the main flow path to the split flow path, and finally, the product with the product core is injected into the center. In the cavity. Due to the low cavity temperature, the organic binder-containing mixture is cooled and solidified.
- the molded blank can be obtained after demolding.
- the injection pressure can be 10--180 MPa.
- the degreasing step means that the organic binder component contained in the blank is removed by degreasing or chemical solution in a high temperature furnace before sintering, and can also be heated and catalytically removed to reduce the carbon content of the blank and increase the density and strength after sintering. .
- the dewaxing can be heat treated in an oven or a high temperature furnace (200-300 ° C), or it can be used, for example, with an alcohol, benzene or other aqueous solvent, or by catalysis in an oven saturated with nitric acid.
- the bead does not require a bead substrate as the supporting underlayer, and therefore, the bead diameter can be made small.
- the diameter of the diamond bead blank can be as small as lmm after sintering, and when the diamond wire saw is made, the outer diameter of the bead is preferably 4 to 5 mm. Further, after the diamond bead blank is sintered, the diameter can be up to 5 mm - 12 mm. Further, the diamond bead can form a complex structure in the MIM injection molding process:
- Both ends of the bead can be slotted
- the beaded surface can be formed into a thread shape
- the bead cavity can be formed into a thread shape
- a bead can be formed at the bottom of the bead
- Both ends of the bead can form a taper.
- the structure of the above 1), 2), 4), 5) is such that the bead end face and the rubber material fixed at both ends form a bite, and the frictional force is increased. During the cutting process, the bead does not slip with the inner core wire rope. , thereby breaking the wire rope.
- the structure of the above 3) is that after the bead surface is formed into a thread shape, the diamond wire saw rotates in the cutting process, and the diamond wire saw bead consumption becomes uniform, which improves the service life of the diamond wire saw.
- the structure of the above 6) is to increase the diameter in the face-to-face cutting direction to balance the loss of diamond beads.
- the beaded ends of the market are also slotted, and the beaded inner cavity can be formed into a thread shape, but all of them are designed on the side surface of the bead inside the bead.
- Our design does not require a base layer, and is directly designed on the side of the cylindrical working layer, and can be molded at one time, without the need for subsequent secondary machining of the thread, which greatly reduces the production cost.
- the present invention also provides a diamond bead wire saw without a base support layer, comprising a plurality of diamond beades, each of which is directly strung on a wire rope or a steel wire and is fixed by a rubber material between adjacent beads.
- the invention utilizes a pre-heat press forming process or a MIM injection molding process and is sintered at one time into a whole Cylindrical beading, the diameter of the finished diamond bead is up to lmm.
- the bead does not need the bead base as the supporting bottom layer, so the outer diameter of the wire saw (bead:) is 4 ⁇ 5mm, and currently Compared with the ⁇ 7.2 mm wide direct wire saw commonly used in the market, the slit is inevitably smaller; in addition, due to the one-time molding, the sintering temperature is controlled reasonably, and the metal powder ratio is reasonable, so the US document US2005271539 (A1) is not required.
- Figure 1 is a schematic cross-sectional view of a conventional diamond bead structure commonly used in the market.
- Figure 2 is a schematic cross-sectional view of a diamond bead with holes at both ends.
- Figure 3 is a front view of a diamond bead with holes at both ends.
- Figure 4 is a front view of a diamond bead without a base with grooves at both ends.
- Figure 5 is a front elevational view of a diamond bead without a substrate and a spiral surface.
- Figure 6 is a schematic cross-sectional view of a diamond bead with a shoulder on the side.
- Figure 7 is a schematic cross-sectional view of a monolithic monolithic diamond wire saw.
- Fig. 8 is a schematic cross-sectional view showing the structure of a preheating press molding die.
- Figure 9. Schematic diagram of the mold cavity of the diamond product metal powder injection molding die. In the figure: A, the base layer, B, the working layer containing diamond particles;
- Diamond working layer 2. Holes at both ends of the whole bead, 3. Dovetail groove at both ends of the whole bead, 4. Thread groove on the surface of the diamond bead, 5. Rubber and plastic material of the diamond wire saw, 6. Wire rope. 7, granular mixture, 8, mold sleeve, 9, lower pressure head, 10, upper pressure head, 11, product cavity, 12, core, 13, the mainstream road, 14, divided into mainstream roads, 15, templates. detailed description
- the invention provides a diamond bead wire saw without a base support layer, which comprises a plurality of diamond beads, each of which is directly stringed on a steel wire rope or a steel line, and is fixed and fixed by a rubber material between adjacent beads. Shoulder or taper of the shoulder, the shoulder or part of the taper is covered by the rubber material and is fixed and isolated. Since the base layer support is not employed in the present invention, the diamond bead used is the wire saw working layer, so that the outermost peripheral diameter of the wire saw (i.e., the bead diameter:) can be greatly reduced to about 4.5 mm.
- the diamond bead therein can be prepared by a conventional process or the following embodiment of the present invention.
- Embodiment 1 A method for preparing diamond beads, comprising the following steps:
- a metal prealloyed powder having a diameter of 0.5 to 20 ⁇ m (weight ratio of Co-20% Ni-10% Cu-28% Fe-30% Cr-3% Sn-5% P-) 3% Si-1%) and 3% of 40/50 mesh diamond were mixed and used.
- the raw material particles 7 are placed in a hot stamping mold in which the cavity is prepared.
- the hot stamping die is composed of a die sleeve 8, a lower indenter 9, an upper indenter 10, and a product cavity 11. After 200 degree hot press forming, after cooling and demoulding, a diamond bead blank can be formed.
- the cylindrical diamond bead blank is degreased in a degreasing furnace at a temperature of 250 degrees.
- a method for preparing a diamond bead comprises the following steps:
- a metal prealloyed powder having a diameter of 0.5 to 20 ⁇ m weight ratio of Co-60% Ni-10% Cu-10% Fe-12% Cr-3% Sn-4% Si-) 1%) and 2.8% of 40/50 diamond are mixed and used.
- the mixed raw materials are made into particles of about 2 diameter.
- the mold consists of the product cavity 11, the core 12, the main channel 13, the main channel 14, and the template 15. After injection molding, a diamond bead blank can be obtained.
- a method for preparing a diamond bead comprises the following steps:
- the mixed raw material is placed in a cold press and cold pressed to obtain a cylindrical diamond bead blank.
- the diameter of the diamond bead finished product was obtained by a single-time sintering to obtain a diamond beaded product having a diameter of 4.5 mm.
- the diamond beaded product is stringed into a steel wire rope to form a diamond wire saw.
- the diamond of the present invention may also be other superhard materials such as cemented carbide, cubic boron oxide, boron carbide, diamond thick film, silicon carbide, aluminum oxide, and mixtures thereof.
- the diamond may also be titanium-plated or coated with elements that are reactively bonded to carbon, such as titanium, chromium, molybdenum, tungsten, boron, silicon, and mixtures thereof to enhance the bonding of diamonds in the metal matrix. Force to improve the service life and efficiency of the working layer.
- the sintering temperature of the diamond bead blank is from 700 ° C to 890 ° C.
- the present invention directly forms the integral cylindrical bead in the MIM injection molding by the above successive steps, and the bead does not require the bead substrate as the supporting underlayer, and therefore, the bead diameter can be made small.
- the diamond bead blank has a diameter of at least lmm after sintering, and the outer diameter of the bead is preferably 4 to 5 mm when the diamond wire saw is made. After the sintered diamond bead blank of the present invention is sintered, the diameter can reach 5 mm - 12 mm.
- the diamond bead produced by the process of the present invention forms a complex structure as follows:
- the ends of the bead may have small holes, as shown in FIG. 2 or FIG. 3, the small holes are the holes 2 at both ends of the whole bead;
- the bead surface can be formed into a thread shape, as shown in Figure 5, the thread groove 4 of the diamond bead surface;
- the bead cavity can be threaded.
- the shoulder of the bead can form a shoulder, as shown in Figure 6.
- Both ends of the bead can form a taper.
- the bead processed by the invention has a diamond working layer 1 and an axial through hole for the wire rope or the steel wire to pass through, a plurality of diamond bead strings on the wire rope 6 or the steel wire, and between the adjacent beads by the diamond
- the rubber wire material 5 of the stone wire saw is isolated and fixed.
- the wire saw of the structure has no base layer, so the outer diameter of the last wire saw product can be controlled below 7 mm, which is suitable for wide-scale promotion.
- the metal powder used in the present invention is composed of all or a part of the following metal components: Co, Ni, Cu, Ti, Cr, B, Si, Sn, P, Mo, Wc, W, Fe.
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Abstract
A diamond bead string, a method for manufacturing same and a diamond bead string wire saw without a matrix support layer. The method for manufacturing the diamond bead string comprises the following steps: evenly mixing metal powder, diamond and an organic binding agent; manufacturing a rough blank of the diamond bead string through pre-hot-pressing molding or metal injection molding (MIM); placing the rough blank in a high-temperature furnace for one-step sintering molding process after degreasing, to obtain a finished product of the diamond bead string. The rough blank is sintered in one step to form an entire cylindrical bead string without a bead string matrix layer, and the external diameter of the bead string becomes smaller, so that a steel wire is directly inserted into the bead string to form a diamond wire saw with a smaller external diameter; the bead string is molded integrated without a last-stage impregnation process, so that the production cost of the diamond bead string is greatly reduced. Furthermore, the diameter of the diamond wire saw is smaller, and a cutting seam of a stone material to be cut is smaller, so that the yield of rough stone blocks is improved. The present invention is beneficial to wide popularization and utilization of the diamond wire saw.
Description
金刚石串珠、 制备方法及无基体支撑层的绳锯 技术领域 Diamond beading, preparation method and wire saw without base support layer
本发明公开一种金刚石串珠、 制备方法及不需要基体支撑层的金刚石绳锯， 按国际专利分类表 (IPC)划分属于金刚石工具元件技术领域， 尤其是涉及一种利 用金属粉末注塑成型工艺 （MIM) 生产金刚石串珠， 该串珠是金刚石绳锯或线锯 的重要构成元件。 The invention discloses a diamond bead, a preparation method and a diamond wire saw which does not require a base supporting layer, and belongs to the technical field of diamond tool components according to the International Patent Classification Table (IPC), in particular to a metal powder injection molding process (MIM) ) Production of diamond beads, which are important components of diamond wire saws or wire saws.
背景技术 Background technique
金刚石绳锯是由圆筒状的金刚石串珠串到钢丝绳上，再通过橡塑间隔套将每 个串珠固定起来， 形成完整的金刚石绳锯， 其中圆筒状的金刚石串珠是由圆筒 状基体层 A和上面的含金刚石颗粒工作层 B构成， 见图 1所示。 这是目前金刚 石串珠的通用结构。 The diamond wire saw is made up of a cylindrical diamond bead string on the wire rope, and each bead is fixed by a rubber spacer to form a complete diamond wire saw, wherein the cylindrical diamond bead is made up of a cylindrical base layer. A and the upper diamond-containing particle working layer B are formed, as shown in FIG. This is the general structure of diamond diamond beads.
金刚石绳锯应用是从 1970年开始并推广的， 由于它长度可针对切割对象的 大小进行调整， 弯曲度好， 对切割环境适用性强， 因而被广泛应用于花岗石、 大理石矿山开采切割及石材加工厂内的异形、 弧形石制品切割等， 另外金刚石 绳锯也可应用于混凝土立柱等建筑的切割。 The application of diamond wire saw has been promoted since 1970. Because its length can be adjusted for the size of the object to be cut, the bending is good, and it has strong applicability to the cutting environment, it is widely used in granite and marble mining and cutting. Shaped and curved stone products in stone processing plants, etc. In addition, diamond wire saws can also be used for the cutting of concrete columns and other buildings.
现有的金刚石绳锯外径 (金刚石串珠)在 Φ 7- Φ 11毫米， 其中， 金刚石串珠基 本生产工艺流程如下： 先将圆筒状串珠基体备好， 将金属粉和金刚石拌匀， 然 后装入金属冷压模上冷压， 即将工作层冷压到串珠基体上， 或者先冷压一工作 层圈再套到基体上， 形成形状相近的粗坯， 然后将冷压好的粗坯置于石墨模具 中， 放入热压机中热压烧结成形。 另一种烧结工艺是将冷压好的粗坯直接放入 氢气炉中烧结成型， 除此之外， 烧结还有采用热等静压工艺。 除以上所述工艺， 还有通过电镀及钎焊工艺将金刚石直接结合在基体表面而形成金刚石串珠， 但
该产品只限用于大理石等软性材料的切割， 否则由于只有单层金刚石而使用寿 命较短。 The existing diamond wire saw outer diameter (diamond bead) is Φ 7- Φ 11 mm, wherein the basic production process of diamond bead is as follows: First, the cylindrical bead substrate is prepared, the metal powder and the diamond are mixed well, and then loaded. Cold pressing on the metal cold stamping die, that is, cold pressing the working layer onto the bead substrate, or first cold pressing a working layer ring and then inserting on the base body to form a rough blank of similar shape, and then placing the cold pressed blank In the graphite mold, it is placed in a hot press to form a hot press. Another sintering process is to directly form a cold pressed blank into a hydrogen furnace for sintering. In addition, sintering is also performed by a hot isostatic pressing process. In addition to the above process, diamond is directly bonded to the surface of the substrate by electroplating and brazing processes to form diamond beads, but This product can only be used for the cutting of soft materials such as marble, otherwise it will have a short service life due to the single layer of diamond.
由于金刚石绳锯生产中， 金刚石串珠的生产工艺主要是冷压成型烧结工艺， 该工艺通常是将原材料放置于普通的冷压成型模具中冷压出初坯， 然后将初坯 和串珠基体一起在高温热压机 （700-900度） 烧结成型或在高温炉中烧结成型。 该传统工艺生产效率较低。 传统生产金刚石串珠的工艺同时涉及到金刚石串珠 中需要设置一个环形基体， 该基体与含金刚石的工作层相结合后成金刚石串珠。 传统金刚石串珠设置一层基体的目的是可在基体内壁加工螺紋状沟槽， 该沟槽 在金刚石串珠与钢丝绳固定时， 串珠旁边的为固定串珠的橡塑材料， 可在橡塑 材料成型时挤入螺紋状沟槽中， 另一方面， 基体层长度比串珠工作层大， 形成 台阶状， 该台阶基体也可嵌入橡塑材料层中， 使得串珠在切割过程中不易转动 而失效。 但是， 1mm左右的基体， 可使得整体金刚石绳锯的外径增加， 生产成 本较高。 另一方面金刚石绳锯的外径增加， 使得切割石材时切缝增大， 造成石 材原料的极大浪费。 例如在花岗岩的切割领域， 一方面金刚石绳锯的每平方米 的切割费用比金刚石圆盘锯或砂锯的成本高， 因而无法取代金刚石圆盘锯和砂 锯的使用； 另一方面目前市场上通用的小直径绳锯， 其外径是 7.2mm， 切缝相 对较宽， 也限制了它花岗石大板的切割使用。 In the production of diamond wire saws, the diamond bead production process is mainly a cold press forming sintering process, which usually involves placing the raw materials in a common cold press forming die, cold pressing the preforms, and then placing the preforms and the bead matrix together at a high temperature. Hot press (700-900 degrees) Sintered or sintered in a high temperature furnace. This traditional process is less efficient. The conventional process of producing diamond bead involves the formation of an annular matrix in the diamond bead, which is combined with a diamond-containing working layer to form a diamond bead. The purpose of the conventional diamond bead is to form a layer of the base body. The threaded groove can be processed on the inner wall of the base. When the diamond bead and the wire rope are fixed, the beaded rubber material is fixed beside the bead, which can be squeezed when the rubber material is formed. In the threaded groove, on the other hand, the length of the base layer is larger than that of the bead working layer, forming a stepped shape, and the stepped base body can also be embedded in the rubber material layer, so that the bead is not easily rotated and fails during the cutting process. However, the base body of about 1 mm can increase the outer diameter of the overall diamond wire saw, and the production cost is high. On the other hand, the outer diameter of the diamond wire saw increases, which increases the slit when cutting the stone, resulting in a great waste of stone material. For example, in the field of granite cutting, on the one hand, the cost per square meter of diamond wire saw is higher than that of diamond circular saw or sand saw, so it cannot replace the use of diamond circular saw and sand saw; The universal small diameter wire saw has an outer diameter of 7.2 mm and a relatively wide slit, which also limits the cutting of its granite slab.
以上这两点因素，使得金刚石绳锯在石材荒料的加工切割方面无法大规模地 推广使用。 These two factors make the diamond wire saw unable to be widely used in the processing and cutting of stone blocks.
为解决大规模生产成本问题，国外文献有论述过利用金属粉末领域的金属粉 末注塑成型 （MIM) 工艺来生产金刚石工具的技术。 该工艺基本原理与金属粉 末注塑成型工艺相类似， 即利用现有的一种制造复杂的金属元件的冶金工艺， 为适合金刚石元件特点而作一些调整创新。 原有的金属粉末注塑成型工艺是首
先将超细金属预合金粉末与聚烯烃等热塑性有机粘结剂均匀混合， 经制粒后置 于注塑机中加热约 150°C， 注塑入已开有产品模的模腔中， 就会固化成型。将固 化成型的粗坯中的有机粘结剂通过脱脂炉或通过化学溶液脱脂等方法脱除有粘 结剂， 最后将毛坯放入高温炉中最终烧结成型。 In order to solve the problem of large-scale production cost, foreign literature has discussed the technology of producing diamond tools by metal powder injection molding (MIM) process in the field of metal powder. The basic principle of the process is similar to that of the metal powder injection molding process, that is, using an existing metallurgical process for manufacturing complex metal components, and making some adjustments and innovations for the characteristics of the diamond components. The original metal powder injection molding process is the first First, the ultrafine metal prealloyed powder is uniformly mixed with a thermoplastic organic binder such as polyolefin, and after being granulated, it is placed in an injection molding machine and heated at about 150 ° C, and is molded into a cavity in which a product mold has been opened, and is solidified. forming. The organic binder in the solidified green compact is removed by a degreasing furnace or by chemical solution degreasing, and finally the blank is placed in a high temperature furnace and finally sintered.
美国文献 US2005271539(A1)， 在中国专利族 CN 1714990， 公开一种金刚石 元件,例如线锯的***物,通过含有以下步骤的方法制备:制备金属粉的起始混合 物， 通过特定的塑性添加剂塑化起始混合物， 添加金刚石颗粒， 通过 MIM技术 注模成型， 去除塑性添加剂， 将已制好的含多层金刚石的毛坯串入金属圆筒基 体上， 再放入高温炉烧结后， 由于成品烧结温度为 900度以上， 烧结的成品含 有很多孔隙， 因而需要再将含孔隙的金刚石串珠再进行渗入 Cu/Ag等低共熔合 金或另一些低温合金进行空隙渗入填埋处理。 但这种工艺的生产成本仍然较高， 原因是一方面， 在烧结成型的金刚石元件上， 形成了很多孔隙， 因此， 后期还 必须增加一道渗透银铜等合金溶液的工序， 由于银铜合金价格较昂贵， 再加上 渗透工序复杂， 因此增加了金刚石串珠的生产成本； 另一方面， 金刚石串珠还 是传统的设计， 即金刚石串珠毛坯需要再装入金属圆筒基体上， 然后再烧结， 这样不仅增加了成本， 也无法制成小直径的多层金刚石串珠。 即使制成例如直 径 5mm的含基体的金刚石串珠， 但由于工作成在基体之上， 也无法有充分的厚 度例如 lmm以上， 从而影响到切割石材的使用寿命。 再次增设金属圆状筒基体 层， 也增加了工艺的复杂性， 从而也增加了成本。 US Patent No. US2005271539 (A1), in the Chinese patent group CN 1714990, discloses a diamond element, such as an insert for a wire saw, prepared by a process comprising the steps of preparing a starting mixture of metal powder, plasticizing it with a specific plastic additive. The starting mixture, adding diamond particles, injection molding by MIM technology, removing plastic additives, and the prepared multilayer diamond-containing blanks are serially connected to the metal cylinder substrate, and then placed in a high temperature furnace for sintering, due to the sintering temperature of the finished product. For more than 900 degrees, the sintered product contains a lot of pores, so it is necessary to infiltrate the porous diamond beads into the eutectic alloy such as Cu/Ag or other low-temperature alloys for void penetration into the landfill. However, the production cost of this process is still high, because on the one hand, a lot of pores are formed on the sintered diamond element. Therefore, a process of infiltrating an alloy solution such as silver and copper must be added in the later stage, due to the price of silver-copper alloy. More expensive, coupled with the complicated infiltration process, thus increasing the production cost of diamond bead; on the other hand, diamond bead is still a traditional design, that is, the diamond bead blank needs to be reloaded into the metal cylinder substrate and then sintered, so that The cost is increased and it is not possible to make small diameter multi-layer diamond beads. Even if a diamond bead containing a substrate of, for example, a diameter of 5 mm is formed, since it is worked on the substrate, it is not possible to have a sufficient thickness such as lmm or more, thereby affecting the service life of the cut stone. The addition of a metal circular cylinder base layer again increases the complexity of the process and thus increases the cost.
发明内容 Summary of the invention
针对现有技术的不足， 本发明提供了一种金刚石串珠及制备方法， 即设计 了一种无基体支撑的的金刚石串珠， 区别于单层电镀或钎焊的金刚石串珠， 该 无基体支撑的的金刚石串珠， 也含有多层金刚石， 从而增加使用寿命， 并且一
次性烧结完成， 无需最后的渗透银铜等合金溶液的工序。 In view of the deficiencies of the prior art, the present invention provides a diamond bead and a preparation method thereof, that is, a diamond bead without a substrate support is designed, which is different from a single layer electroplated or brazed diamond bead, the substrateless support Diamond beading, also containing multiple layers of diamond, increasing the service life, and The secondary sintering is completed, and the final process of infiltrating an alloy solution such as silver or copper is not required.
为达到上述目的， 本发明是通过以下技术方案实现的： In order to achieve the above object, the present invention is achieved by the following technical solutions:
一种金刚石串珠的制备方法， 包括如下步骤： A method for preparing diamond bead comprises the following steps:
1)、 将金属粉、 金刚石和有机结合剂混合均匀； 1), mixing metal powder, diamond and organic binder evenly;
2)、 制成金刚石串珠粗坯； 2), making a diamond bead blank;
3)、 脱脂后将粗坯放入真空炉或氢气炉或高温炉中一次性烧结成型得到金 刚石串珠成品。 为了避免金刚石与金属粉混合物烧结成型后， 产品内部形成较多的孔隙。 我们一方面将金属粉的配方进行合理设计，我们将少量的 B、 Si、 P等元素引入， 将之与 Co,Cr,Ni,W,WC,Mn,Fe,Cu,Sn,Mo的部分或全部形成合金。在烧结时 B,Si,P 等元素可降低金属粉烧结温度， 并在烧结过程消除空隙。 以上金属及非金属可 制成预合金粉末。 另一方面， 为了减少金刚石串珠直径， 我们采取不需要金刚 石串珠基体的设计。 3) After degreasing, the rough blank is placed in a vacuum furnace or a hydrogen furnace or a high-temperature furnace for one-time sintering to obtain a diamond beaded product. In order to avoid sintering of the diamond and metal powder mixture, more pores are formed inside the product. On the one hand, we rationally design the formulation of metal powder. We introduce a small amount of elements such as B, Si, P, etc., with parts of Co, Cr, Ni, W, WC, Mn, Fe, Cu, Sn, Mo or All form an alloy. At the time of sintering, elements such as B, Si, and P can lower the sintering temperature of the metal powder and eliminate voids during the sintering process. The above metals and non-metals can be made into pre-alloyed powders. On the other hand, in order to reduce the diameter of the diamond bead, we adopt a design that does not require a diamond bead matrix.
制成毛坯的一种工艺是， 即采取 "预热压成型工艺"。 该工艺是将混合料颗 粒 （包含金刚石、 热塑性结合剂、 金属粉）， 放入钢模中在温度为 10°C— 250°C 的中温热压机中热压成型，或在温度为 100°C— 250°C的模腔中加压成型粗坯 (毛 坯）。 One process for making a blank is to take a "pre-heat forming process". The process involves hot-press molding of the mixture particles (including diamond, thermoplastic binder, metal powder) in a steel mold at a medium temperature hot press at a temperature of 10 ° C to 250 ° C, or at a temperature of 100. Pressing and forming a blank (blank) in a cavity of °C - 250 °C.
具体的步骤是， 首先将金属预合金粉末与金刚石混合均匀后， 添加石蜡、 聚乙烯等有机粘结剂后， 在密炼机上混料造粒， 也可以在中温拌料机上将金属 预合金粉末、 金刚石及有机粘结剂揉合均匀后， 制成直径 Φ 3mm左右的颗粒， 然后将这些颗粒定量装入模具 （见图 7) 中， 放置于温度 100-200 °C的平板压机 上热压。 该模具在热压时， 由于颗粒状原料在约 200°C的模腔中软化， 加压时模
具漏斗上的原料挤压进入底下模腔里成型。 最后将模具冷却脱模后便制得圆筒 状毛坯。将毛坯放入脱脂炉中脱去有机粘结剂后， 在高温炉中 860°C烧结成型为 最终广品。 The specific steps are as follows: firstly, the metal prealloyed powder is uniformly mixed with the diamond, and then an organic binder such as paraffin or polyethylene is added, and then mixed and granulated on the internal mixer, and the metal prealloyed powder can also be mixed on the medium temperature mixer. After the diamond and the organic binder are uniformly kneaded, the particles having a diameter of about 3 mm are prepared, and then the particles are quantitatively loaded into a mold (see Fig. 7) and placed on a flat plate press at a temperature of 100-200 °C. Pressure. When the mold is hot pressed, the granular material is softened in a cavity of about 200 ° C, and the mold is pressed. The raw material on the funnel is extruded into the bottom cavity to form. Finally, the mold is cooled and demolded to obtain a cylindrical blank. The blank was placed in a degreasing furnace to remove the organic binder, and then sintered at 860 ° C in a high temperature furnace to form a final product.
进一步， 所述的金刚石也可以是其它超硬材料， 例如硬质合金、 立方氧化 硼、 碳化硼、 金刚石厚膜、 碳化硅、 氧化铝以及它们的混合物。 进一步， 所述的金刚石也可以是表面镀钛或包裹有与碳易发生反应键合的 元素， 例如钛、 铬、 钼、 钨、 硼、 硅及它们的混合物， 以提高金刚石在金属胎 体中的结合力， 提高工作层的使用寿命及效率。 Further, the diamond may also be other superhard materials such as cemented carbide, cubic boron oxide, boron carbide, diamond thick film, silicon carbide, aluminum oxide, and mixtures thereof. Further, the diamond may also be surface-plated with titanium or coated with elements reactive with carbon, such as titanium, chromium, molybdenum, tungsten, boron, silicon, and mixtures thereof to enhance diamond in the metal matrix. The combination of strength, improve the life and efficiency of the working layer.
将已经压好的含有金刚石的圆筒状粗坯， 通过脱脂炉脱脂后， 放入真空炉， 也可以是含有保护气体或还原气体的高温炉中烧结成型。 The already-crushed cylindrical green compact containing diamond is degreased in a degreasing furnace and then placed in a vacuum furnace, or may be sintered in a high-temperature furnace containing a protective gas or a reducing gas.
进一步， 所述的金刚石串珠粗坯的烧结温度为 700°C— 890°C。 制成金刚石串珠毛坯的另一种方法是利用金属粉末注塑成型工艺， 直接形 成整体圆筒状串珠。 该工艺是将混合料颗粒 （包含金刚石、 热塑性结合剂、 金 属粉）， 放入注塑机中， 注塑成型， 便得到毛坯。 金刚石制品金属粉末注塑成型制造工艺流程如下： Further, the sintered diamond bead blank has a sintering temperature of 700 ° C to 890 ° C. Another method of making a diamond bead blank is to directly form a unitary cylindrical bead using a metal powder injection molding process. In the process, the mixture particles (including diamond, thermoplastic binder, metal powder) are placed in an injection molding machine and injection molded to obtain a blank. The diamond product metal powder injection molding manufacturing process is as follows:
金属粉末、 金刚石、 有机粘接剂一混料一成型一脱脂一烧结一后处理一成 品一串入钢丝绳一将串珠间隔注塑包裹成为完整的金刚石绳锯。 Metal powder, diamond, organic binder, a mixture, a molding, a degreasing, a sintering, a post-treatment, a product, a string into a wire rope, and a beaded injection molding into a complete diamond wire saw.
注射成型步骤是： 将含有机粘合剂的混合料制成颗粒状后， 加到注塑机料 柜中加热熔化后， 在注塑机螺杆的压力下， 将熔融状态的混合料注入已设计好 制品形状的模腔内， 由于模腔温度低， 因而含有机粘合剂的混合料就冷却固化 成型。 脱模后便可得成型毛坯。 注塑压力可为 10--180Mpa。 The injection molding step is: after the mixture containing the organic binder is granulated, and then heated and melted in the injection molding machine cabinet, the molten material is injected into the designed product under the pressure of the screw of the injection molding machine. In the cavity of the shape, the mixture containing the organic binder is cooled and solidified due to the low temperature of the cavity. The molded blank can be obtained after demolding. The injection pressure can be 10--180 MPa.
预热压成型工艺与金属粉末注塑成型工艺的区别在于以下步骤中的金属粉
末、 金刚石、 有机粘接剂一混料一成型有些区别， 即预热压成型工艺是原材料 混合物在热压机里成型， 而金属粉末注塑成型工艺 （MIM) 原材料混合物在热压 机里成型。 而脱脂一烧结一后处理一成品工艺则相同。 The difference between the pre-heat forming process and the metal powder injection molding process lies in the metal powder in the following steps. At the end, diamond and organic binder-mixing are somewhat different. The pre-heat forming process is that the raw material mixture is formed in a hot press, and the metal powder injection molding process (MIM) raw material mixture is formed in a hot press. The process of treating a finished product after degreasing, sintering, and the like is the same.
如上所述， 金属粉末注塑成型工艺具体流程为： As mentioned above, the specific process of the metal powder injection molding process is:
金属粉末、 金刚石、 有机粘接剂一混料一成型一脱脂一烧结一后处理一成 金属粉末及配方的设计， 是为了更好地降低烧结温度， 一方面是较低温度 烧结， 可减少金刚石强度在高温烧结炉中的下降程度。 另一方面， 合理的金属 粉末及配方的设计， 也可避免烧结的产品含有较多气孔而需要再次处理。 Metal powder, diamond, organic binder-mixing, forming, degreasing, sintering, post-treatment, metal powder and formulation design, in order to better reduce the sintering temperature, on the one hand, lower temperature sintering, reducing diamond The degree of strength reduction in a high temperature sintering furnace. On the other hand, reasonable metal powders and formulations are designed to prevent the sintered product from containing more pores and requiring further treatment.
我们采取的金属预合金粉， 粒度尺寸在 0. 5-20um， 以便有利于烧结。 The metal prealloyed powder we have adopted has a particle size of 0. 5-20 um in order to facilitate sintering.
为避免烧结后制品易形成很多气孔， 首先我采取在金属粉末中加入能降低 金属熔点的非金属元素 P， Si等， 再次是降低烧结温度为 750-890°C左右。 这样 通过此措施， 烧结后串珠密度较高无气孔。 金属粉成分是 B、 P、 Si, 它们的部 分或全部和由以下全部或部分金属成分构成的： Co、 Ni、 Cu、 Ti、 Cr、 Sn、 Mo、 Wc、 W、 Fe、 Mn。 In order to avoid the formation of many pores after sintering, firstly, I added a non-metallic element P, Si, etc. which can lower the melting point of the metal in the metal powder, and again reduce the sintering temperature to about 750-890 °C. Thus, by this measure, the bead density is higher after sintering without voids. The metal powder component is B, P, Si, and some or all of them are composed of all or part of the following metal components: Co, Ni, Cu, Ti, Cr, Sn, Mo, Wc, W, Fe, Mn.
有机结合剂由热塑性树脂、 增塑剂及润滑剂组成， 一般不超过整个体积比 的 40%。 一般选用聚乙烯、 石蜡、 硬脂酸等。 也可以选用其它有机粘结剂， 例如 聚丙烯、 醋酸乙基乙烯基酯、 聚乙烯碳酸盐、 聚乙二烯、 石蜡、 硬脂酸、 聚乙
烯醇、 纤维素化合物和多糖的水溶性热塑性混合物、 聚缩醛类热塑性混合物和 热固性混合物等。 有机结合剂体积比例为 25-50%, 30-40%较好。 The organic binder is composed of a thermoplastic resin, a plasticizer and a lubricant, and generally does not exceed 40% of the entire volume ratio. Generally, polyethylene, paraffin, stearic acid and the like are used. Other organic binders such as polypropylene, ethyl vinyl acetate, polyethylene carbonate, polyvinylidene, paraffin, stearic acid, polyethyl b can also be used. A water-soluble thermoplastic mixture of an enol, a cellulose compound and a polysaccharide, a polyacetal thermoplastic mixture, a thermosetting mixture, and the like. The organic binder has a volume ratio of 25-50%, preferably 30-40%.
混料步骤是将金刚石及金属粉混合物与有机粘结剂揉合均匀， 通过掺混揉 合， 使有机粘结剂和混合物料成为一体， 在热塑机中流动过程中互不分离， 以 提高制品的各向密度的均一性。 这样在烧结过程 中， 制品可保持原有的形状， 各向强度一致。 混合可在双螺丝挤压机型或双辊混合器、 Z-型叶片或∑-型叶片 的行星式混合器中进行。 The mixing step is to uniformly mix the diamond and the metal powder mixture with the organic binder, and the organic binder and the mixture material are integrated by blending and kneading, and are not separated from each other during the flow in the thermoplastic machine to improve The uniformity of the isotropic density of the article. In this way, the product can maintain its original shape during the sintering process, and the strength of each direction is uniform. Mixing can be carried out in a twin-screw extruder or twin-roll mixer, Z-vane or ∑-blade planetary mixer.
将含有机粘合剂的混合料制成颗粒状后， 加到注塑机料柜中加热熔化后， 在注塑机螺杆的压力下， 将熔融状态的混合料注入已设计好制品形状的注塑模 内， 注塑模腔内设计有混合料流动的主流道、 分流道、 产品模芯、 产品腔体等， 注塑时产品时， 混合料从主流道流向分流道， 最后注入中心设有产品模芯的产 品腔体里。 由于模腔温度低， 因而含有机粘合剂的混合料就冷却固化成型。 脱 模后便可得成型毛坯。 注塑压力可为 10--180Mpa。 After the mixture containing the organic binder is granulated, it is heated and melted in the injection molding machine cabinet, and the molten material is injected into the injection mold of the designed product shape under the pressure of the screw of the injection molding machine. In the injection mold cavity, the main flow path of the mixed material flow, the split flow path, the product mold core, the product cavity, etc. are designed. When the product is injected, the mixed material flows from the main flow path to the split flow path, and finally, the product with the product core is injected into the center. In the cavity. Due to the low cavity temperature, the organic binder-containing mixture is cooled and solidified. The molded blank can be obtained after demolding. The injection pressure can be 10--180 MPa.
脱脂步骤是指在烧结前将毛坯内所含的有机粘结剂成分通过高温炉脱脂或 化学溶液进行清除， 也可以加温催化清除， 以降低毛坯的含碳量， 提高烧结后 的密度及强度。 The degreasing step means that the organic binder component contained in the blank is removed by degreasing or chemical solution in a high temperature furnace before sintering, and can also be heated and catalytically removed to reduce the carbon content of the blank and increase the density and strength after sintering. .
脱蜡可以在烘箱或高温炉中加热处理（200-300°C )， 也可使用例如醇、苯或 其它含水溶剂， 或者通过在用硝酸饱和的烘箱中的催化作用。 The dewaxing can be heat treated in an oven or a high temperature furnace (200-300 ° C), or it can be used, for example, with an alcohol, benzene or other aqueous solvent, or by catalysis in an oven saturated with nitric acid.
以上工艺中， 该串珠不需要串珠基体作为支撑底层， 因此， 可使得串珠直 径变小。 通过以上方法， 金刚石串珠粗坯在烧结后直径最小可达 lmm， 在制成金刚 石绳锯时， 串珠外径最佳为 4〜5mm。 进一步， 所述的金刚石串珠粗坯烧结后， 直径可达 5mm— 12mm。
进一步， 所述的金刚石串珠在 MIM注塑成型工艺中可形成一种下面复杂的 结构： In the above process, the bead does not require a bead substrate as the supporting underlayer, and therefore, the bead diameter can be made small. Through the above method, the diameter of the diamond bead blank can be as small as lmm after sintering, and when the diamond wire saw is made, the outer diameter of the bead is preferably 4 to 5 mm. Further, after the diamond bead blank is sintered, the diameter can be up to 5 mm - 12 mm. Further, the diamond bead can form a complex structure in the MIM injection molding process:
1 ) 串珠两端可带有小孔； 1) There may be small holes at both ends of the bead;
2 ) 串珠两端可开槽； 2) Both ends of the bead can be slotted;
3 ) 串珠表面可形成螺紋状； 3) the beaded surface can be formed into a thread shape;
4) 串珠内腔可形成螺紋状； 4) The bead cavity can be formed into a thread shape;
5 ) 串珠底部可形成凸肩； 5) a bead can be formed at the bottom of the bead;
6) 串珠两头可形成锥度。 6) Both ends of the bead can form a taper.
以上 1 )、 2 )、 4)、 5 ) 的结构目的是， 使串珠端面和两端固定的橡塑材料形 成咬合， 摩擦力增大， 在切割过程中， 串珠不会和内芯钢丝绳产生滑动， 从而 使钢丝绳断裂。 以上 3 ) 的结构目的是， 串珠表面形成螺紋状后， 金刚石绳锯在 切割过程中， 相对于石材整条会自行转动而使得金刚石绳锯串珠消耗变得均一， 提高了金刚石绳锯使用寿命。 以上 6 ) 的结构目的是， 在迎面切割方向， 直径加 大一些， 以平衡金刚石串珠的损耗。 而目前市场上的串珠两端也有开槽， 串珠 内腔可形成螺紋状， 但都是通过设计在串珠内部的基体上的侧面上的。 而我们 的设计不需基体层， 且都是直接设计在圆筒状工作层的侧面上， 且可以一次成 型， 也不需后续二次加工螺紋等， 大大降低了生产成本。 本发明还提供一种无基体支撑层的金刚石串珠绳锯， 其包含若干金刚石串 珠， 各串珠直接串于钢丝绳或钢性线条上， 且在相邻串珠之间由橡塑材料隔离 固定。 The structure of the above 1), 2), 4), 5) is such that the bead end face and the rubber material fixed at both ends form a bite, and the frictional force is increased. During the cutting process, the bead does not slip with the inner core wire rope. , thereby breaking the wire rope. The structure of the above 3) is that after the bead surface is formed into a thread shape, the diamond wire saw rotates in the cutting process, and the diamond wire saw bead consumption becomes uniform, which improves the service life of the diamond wire saw. The structure of the above 6) is to increase the diameter in the face-to-face cutting direction to balance the loss of diamond beads. At present, the beaded ends of the market are also slotted, and the beaded inner cavity can be formed into a thread shape, but all of them are designed on the side surface of the bead inside the bead. Our design does not require a base layer, and is directly designed on the side of the cylindrical working layer, and can be molded at one time, without the need for subsequent secondary machining of the thread, which greatly reduces the production cost. The present invention also provides a diamond bead wire saw without a base support layer, comprising a plurality of diamond beades, each of which is directly strung on a wire rope or a steel wire and is fixed by a rubber material between adjacent beads.
本发明利用预热压成型工艺或 MIM注塑成型工艺并一次性烧结成型为整体
圆筒状串珠，所得到金刚石串珠成品直径最小可达 lmm，在制得金刚石绳锯时， 该串珠不需要串珠基体作为支撑底层， 因此绳锯（串珠：)外径在 4〜5mm， 与目前 市场上常用的大于 Φ 7.2毫米宽直接绳锯相比， 切缝必然会变小； 另外， 由于一 次性成型， 而烧结温度控制合理， 金属粉配比合理， 因此不需要美国文献 US2005271539(A1)提到的制造含基体的金刚石串珠， 并且不需要该工艺中的最 后一道渗透工序， 也极大降低了成本。 通过实验， 利用本发明制作的金刚石绳 锯的每平方米的切割费用比普通金刚石绳锯的成本降低 20%以上。 附图说明 The invention utilizes a pre-heat press forming process or a MIM injection molding process and is sintered at one time into a whole Cylindrical beading, the diameter of the finished diamond bead is up to lmm. When the diamond wire saw is made, the bead does not need the bead base as the supporting bottom layer, so the outer diameter of the wire saw (bead:) is 4~5mm, and currently Compared with the Φ 7.2 mm wide direct wire saw commonly used in the market, the slit is inevitably smaller; in addition, due to the one-time molding, the sintering temperature is controlled reasonably, and the metal powder ratio is reasonable, so the US document US2005271539 (A1) is not required. The manufacture of diamond beads containing a matrix is mentioned and does not require the last infiltration process in the process, which also greatly reduces the cost. Through experiments, the cost per square meter of the diamond wire saw made by the present invention is reduced by more than 20% compared to the cost of a conventional diamond wire saw. DRAWINGS
图 1为现有市场上常用的金刚石串珠结构剖面示意图。 Figure 1 is a schematic cross-sectional view of a conventional diamond bead structure commonly used in the market.
图 2为两端带孔的金刚石串珠剖面示意图。 图 3为两端带孔的金刚石串珠正面示意图。 图 4为两端无基体带槽的金刚石串珠正面示意图。 图 5为无基体、 表面为螺旋结构的金刚石串珠正面示意图。 图 6为侧面有凸肩的金刚石串珠剖面示意图。 图 7为无基体整体金刚石绳锯剖面示意图。 图 8为预热压成型模具结构剖面示意图。 图 9金刚石制品金属粉末注塑成型模具模腔示意图。 图中 ： A、 基体层， B、 含金刚石颗粒工作层； Figure 2 is a schematic cross-sectional view of a diamond bead with holes at both ends. Figure 3 is a front view of a diamond bead with holes at both ends. Figure 4 is a front view of a diamond bead without a base with grooves at both ends. Figure 5 is a front elevational view of a diamond bead without a substrate and a spiral surface. Figure 6 is a schematic cross-sectional view of a diamond bead with a shoulder on the side. Figure 7 is a schematic cross-sectional view of a monolithic monolithic diamond wire saw. Fig. 8 is a schematic cross-sectional view showing the structure of a preheating press molding die. Figure 9. Schematic diagram of the mold cavity of the diamond product metal powder injection molding die. In the figure: A, the base layer, B, the working layer containing diamond particles;
1、 金刚石工作层， 2、 整体串珠两端的孔眼， 3、 整体串珠两端的燕尾槽， 4、 金刚石串珠表面的螺紋沟槽， 5、 金刚石绳锯的橡塑材料， 6、 钢丝绳。 7、 颗粒混合料， 8、 模套， 9、 下压头， 10、 上压头， 11、 产品腔体， 12、 模芯，
13、 主流道， 14、 分主流道， 15、 模板。 具体实施方式 1. Diamond working layer, 2. Holes at both ends of the whole bead, 3. Dovetail groove at both ends of the whole bead, 4. Thread groove on the surface of the diamond bead, 5. Rubber and plastic material of the diamond wire saw, 6. Wire rope. 7, granular mixture, 8, mold sleeve, 9, lower pressure head, 10, upper pressure head, 11, product cavity, 12, core, 13, the mainstream road, 14, divided into mainstream roads, 15, templates. detailed description
下面结合附图对本发明作进一步说明： The present invention will be further described below in conjunction with the accompanying drawings:
本发明提供一种无基体支撑层的金刚石串珠绳锯， 其包含若干金刚石串珠， 各串珠直接串于钢丝绳或钢性线条上， 且在相邻串珠之间由橡塑材料隔离固定， 而带有凸肩或锥度的串珠， 其凸肩或部分锥度由橡塑材料包包覆并隔离固定。 由于本发明中没有采用基体层支撑， 所用的金刚石串珠即绳锯工作层， 因此， 可使绳锯的最外周直径 (即串珠直径:)大大缩小至 4.5mm左右。 其中的金刚石串 珠可采用传统工艺或本发明如下实施例制备。 The invention provides a diamond bead wire saw without a base support layer, which comprises a plurality of diamond beads, each of which is directly stringed on a steel wire rope or a steel line, and is fixed and fixed by a rubber material between adjacent beads. Shoulder or taper of the shoulder, the shoulder or part of the taper is covered by the rubber material and is fixed and isolated. Since the base layer support is not employed in the present invention, the diamond bead used is the wire saw working layer, so that the outermost peripheral diameter of the wire saw (i.e., the bead diameter:) can be greatly reduced to about 4.5 mm. The diamond bead therein can be prepared by a conventional process or the following embodiment of the present invention.
实施例 1 : 一种金刚石串珠的制备方法， 包括如下步骤： Embodiment 1 : A method for preparing diamond beads, comprising the following steps:
1)、 将备好的直径为 0. 5-20微米的金属预合金粉末 （重量比为 Co-20% Ni-10% Cu-28% Fe-30% Cr-3% Sn-5% P-3% Si-1% ) 和 3%的 40/50 目 金刚石混合后备用。 1), a metal prealloyed powder having a diameter of 0.5 to 20 μm (weight ratio of Co-20% Ni-10% Cu-28% Fe-30% Cr-3% Sn-5% P-) 3% Si-1%) and 3% of 40/50 mesh diamond were mixed and used.
2 )将含有体积比为 70%金刚石的金属粉和 15%石蜡和 14. 5%聚乙烯， 硬脂酸 0. 5%, 在温度为 200度， 在有气氛保护状态下的金属混料桶中混合均匀。 2) A metal mixing tank containing a metal powder having a volume ratio of 70% diamond and 15% paraffin wax and 14.5% polyethylene, stearic acid 0.5% at a temperature of 200 degrees in an atmosphere-protected state Mix evenly.
3)、 将混合好的原料 (颗粒混合料 7)， 制成直径 2 左右的颗粒。 3), mix the raw materials (granular mixture 7) to make particles with a diameter of about 2.
4 ) 将原料颗粒 7装入已备好模腔的热压模中， 如图 8所示， 热压模由模套 8、 下压头 9， 上压头 10， 产品腔体 11组成。 在 200度热压成型， 冷却脱模后 便可形成金刚石串珠粗坯。 4) The raw material particles 7 are placed in a hot stamping mold in which the cavity is prepared. As shown in Fig. 8, the hot stamping die is composed of a die sleeve 8, a lower indenter 9, an upper indenter 10, and a product cavity 11. After 200 degree hot press forming, after cooling and demoulding, a diamond bead blank can be formed.
5 ) 将圆筒状金刚石串珠粗坯放入脱脂炉中脱脂， 温度为 250度。 5) The cylindrical diamond bead blank is degreased in a degreasing furnace at a temperature of 250 degrees.
6 )、 脱脂后将粗坯放入真空炉中， 将温度升为 860度， 一次性烧结成型得 到直径 4. 5mm的金刚石串珠成品。
实施例 2 : —种金刚石串珠的制备方法， 包括如下步骤： 5毫米的钻石串珠成品, After the degreasing, the rough is placed in a vacuum furnace, the temperature is raised to 860 degrees, a single-time sintering to obtain a diamond bead finished product having a diameter of 4.5 mm. Embodiment 2: A method for preparing a diamond bead comprises the following steps:
1)、 将备好的直径为 0. 5-20微米的金属预合金粉末 （重量比为 Co-60% Ni-10% Cu-10% Fe-12% Cr-3% Sn-4% Si-1% ) 和 2.8%的 40/50的金刚 石混合后备用。 1), a metal prealloyed powder having a diameter of 0.5 to 20 μm (weight ratio of Co-60% Ni-10% Cu-10% Fe-12% Cr-3% Sn-4% Si-) 1%) and 2.8% of 40/50 diamond are mixed and used.
2 )将含有金刚石的金属粉和少量石蜡和聚乙烯在温度为 200度的状态下混 合均匀。 2) Mix the diamond-containing metal powder with a small amount of paraffin and polyethylene at a temperature of 200 °C.
3)、 将混合好的原料制成直径 2 左右的颗粒。 3), the mixed raw materials are made into particles of about 2 diameter.
4 ) 将颗粒料放入注塑机的料筒中加热， 通过注塑机注入模具中， 如图 9 模具由产品腔体 11， 模芯 12， 主流道 13， 分主流道 14， 模板 15等组成。 注塑 成型后， 便可得到金刚石串珠粗坯。 4) Put the pellets into the barrel of the injection molding machine and heat them into the mold through the injection molding machine. As shown in Fig. 9, the mold consists of the product cavity 11, the core 12, the main channel 13, the main channel 14, and the template 15. After injection molding, a diamond bead blank can be obtained.
5 ) 将圆筒状金刚石串珠粗坯放入脱脂炉中脱脂。 5) Put the cylindrical diamond bead blank into the degreasing furnace for degreasing.
6 )、 脱脂后将粗坯放入真空炉中， 将温度升为 860度， 一次性烧结成型得 到直径 4. 5mm的金刚石串珠成品。 实施例 3 : —种金刚石串珠的制备方法， 包括如下步骤： 6) After degreasing, the rough blank is placed in a vacuum furnace, the temperature is raised to 860 degrees, and a diamond bead finished product having a diameter of 4. 5 mm is obtained by one-time sintering. Embodiment 3: A method for preparing a diamond bead comprises the following steps:
1)、 将备好的直径为 0. 5-20微米的金属预合金粉末 （重量比为 Co-80% Cu-15% Sn-5% ) 和目数 40/50的金刚石 （含量 2. 5%) 混合后备用。 1), a metal prealloyed powder having a diameter of 0. 5-20 microns (weight ratio of Co-80% Cu-15% Sn-5%) and a diamond of 40/50 mesh (content 2. 5) %) Mix and reserve.
2 ) 将含有金刚石的金属粉和少量石蜡在温度为常温的状态下混合均匀。2) Mix the diamond-containing metal powder and a small amount of paraffin wax at a normal temperature.
4 ) 将混合好的原料放入冷压机中冷压便可得到圆筒状金刚石串珠粗坯。4) The mixed raw material is placed in a cold press and cold pressed to obtain a cylindrical diamond bead blank.
6 ) 将粗坯放入金刚石工具氢气烧结炉中， 将温度升为 880度， 一次性烧结 成型得到直径 4. 5mm的金刚石串珠成品。 将金刚石串珠成品串入钢丝绳中， 再制成金刚石绳锯。
上述三种实施例中， 本发明的金刚石也可以是其它超硬材料， 例如硬质合 金、 立方氧化硼、 碳化硼、 金刚石厚膜、 碳化硅、 氧化铝以及它们的混合物。 所述的金刚石也可以是表面镀钛或包裹有与碳易发生反应键合的元素， 例如钛、 铬、 钼、 钨、 硼、 硅及它们的混合物， 以提高金刚石在金属胎体中的结合力， 提高工作层的使用寿命及效率。 本发明各实施例中， 金刚石串珠粗坯的烧结温度为 700°C— 890°C。 5毫米的钻石串珠成品, The diameter of the diamond bead finished product was obtained by a single-time sintering to obtain a diamond beaded product having a diameter of 4.5 mm. The diamond beaded product is stringed into a steel wire rope to form a diamond wire saw. In the above three embodiments, the diamond of the present invention may also be other superhard materials such as cemented carbide, cubic boron oxide, boron carbide, diamond thick film, silicon carbide, aluminum oxide, and mixtures thereof. The diamond may also be titanium-plated or coated with elements that are reactively bonded to carbon, such as titanium, chromium, molybdenum, tungsten, boron, silicon, and mixtures thereof to enhance the bonding of diamonds in the metal matrix. Force to improve the service life and efficiency of the working layer. In various embodiments of the present invention, the sintering temperature of the diamond bead blank is from 700 ° C to 890 ° C.
在实施例 2中， 本发明通过上述连续步骤， 金刚石串珠在 MIM注塑中直接 形成整体圆筒状串珠， 该串珠不需要串珠基体作为支撑底层， 因此， 可使得串 珠直径变小。 所述的金刚石串珠粗坯， 在烧结后直径最小可达 lmm， 在制成金 刚石绳锯时， 串珠外径最佳为 4〜5mm。本发明的金刚石串珠粗坯烧结后， 直径 可达 5mm― 12mm。 本发明工艺制作的金刚石串珠形成一种下面复杂的结构： In the second embodiment, the present invention directly forms the integral cylindrical bead in the MIM injection molding by the above successive steps, and the bead does not require the bead substrate as the supporting underlayer, and therefore, the bead diameter can be made small. The diamond bead blank has a diameter of at least lmm after sintering, and the outer diameter of the bead is preferably 4 to 5 mm when the diamond wire saw is made. After the sintered diamond bead blank of the present invention is sintered, the diameter can reach 5 mm - 12 mm. The diamond bead produced by the process of the present invention forms a complex structure as follows:
1 ) 串珠两端可带有小孔， 如图 2或图 3所示， 所述小孔是整体串珠两端 的孔眼 2; 1) the ends of the bead may have small holes, as shown in FIG. 2 or FIG. 3, the small holes are the holes 2 at both ends of the whole bead;
2 ) 串珠两端可开槽， 如图 4， 所开槽是整体串珠两端的燕尾槽 3; 2) The ends of the bead can be slotted, as shown in Fig. 4, the slot is the dovetail slot 3 at both ends of the whole bead;
3 ) 串珠表面可形成螺紋状， 如图 5， 金刚石串珠表面的螺紋沟槽 4; 3) the bead surface can be formed into a thread shape, as shown in Figure 5, the thread groove 4 of the diamond bead surface;
4) 串珠内腔可形成螺紋状。 4) The bead cavity can be threaded.
5 ) 串珠底部可形成凸肩， 如图 6。 5) The shoulder of the bead can form a shoulder, as shown in Figure 6.
6) 串珠两头可形成锥度。 本发明加工的串珠具有金刚石工作层 1 及轴向通孔用于钢丝绳或钢性线条 穿过， 若干个金刚石串珠串在钢丝绳 6或钢性线条， 且在相邻串珠之间由金刚
石绳锯的橡塑材料 5隔离固定， 如图 7， 该结构的绳锯是没有基体层， 因此最后 的绳锯产品外径可控制在 7毫米以下， 适于大范围推广。 本发明所用的金属粉是由以下全部或部分金属成分构成的： Co、 Ni、 Cu、 Ti、 Cr、 B、 Si、 Sn、 P、 Mo、 Wc、 W、 Fe。 以上所记载， 仅为利用本创作技术内容的实施例， 任何熟悉本项技艺者运用本 创作所做的修饰、 变化， 皆属本创作主张的专利范围， 而不限于实施例所揭示 者。
6) Both ends of the bead can form a taper. The bead processed by the invention has a diamond working layer 1 and an axial through hole for the wire rope or the steel wire to pass through, a plurality of diamond bead strings on the wire rope 6 or the steel wire, and between the adjacent beads by the diamond The rubber wire material 5 of the stone wire saw is isolated and fixed. As shown in Fig. 7, the wire saw of the structure has no base layer, so the outer diameter of the last wire saw product can be controlled below 7 mm, which is suitable for wide-scale promotion. The metal powder used in the present invention is composed of all or a part of the following metal components: Co, Ni, Cu, Ti, Cr, B, Si, Sn, P, Mo, Wc, W, Fe. The above descriptions are merely examples of the use of the content of the present invention, and any modifications and variations made by those skilled in the art using the present invention are the scope of patents claimed herein, and are not limited to those disclosed in the embodiments.
Claims
1、 一种金刚石串珠的制备方法， 其特征在于包括如下步骤： 1. A method for preparing diamond beads, which is characterized by comprising the following steps:
1)、 将金属预合金粉末、 金刚石和有机结合剂混合均匀； 1). Mix the metal pre-alloy powder, diamond and organic binder evenly;
2)、 通过预热压成型工艺或 MIM注塑成型工艺， 也可以利用冷压成型工艺 制成金刚石串珠粗坯； 2). Diamond bead rough blanks can be made through preheating pressing molding process or MIM injection molding process, or cold pressing molding process;
3)、 采用预热压成型或 MIM注塑成型经脱脂后将粗坯放入真空炉或氢气炉 等高温炉中一次性烧结成型得到金刚石串珠成品， 而冷压成型工艺时可直接将 粗坯放入真空炉或氢气炉等高温炉中一次性烧结成型得到不需要基体支撑层的 金刚石串珠成品。 3). Using preheating press molding or MIM injection molding, after degreasing, the rough blank is placed in a high-temperature furnace such as a vacuum furnace or a hydrogen furnace for one-time sintering and molding to obtain the finished diamond beaded product. During the cold pressing molding process, the rough blank can be directly placed. It is put into a high-temperature furnace such as a vacuum furnace or a hydrogen furnace and sintered in one go to obtain a finished diamond bead product that does not require a matrix support layer.
2、 根据权利要求 1所述的金刚石串珠的制备方法， 其特征在于： 所述的金 属预合金粉末是由降低烧结温度的非金属元素 B、 Si、 P的全部或部分和以下全 部或部分金属成分构成的： Co、 Ni、 Cu、 Ti、 Cr、 Sn、 Mo、 Wc、 W、 Fe、 Mn， 其中金属预合金粉末中非金属元素占全部质量的 10%以下。 2. The preparation method of diamond beads according to claim 1, characterized in that: the metal pre-alloyed powder is made of all or part of the non-metallic elements B, Si, P and all or part of the following metals that reduce the sintering temperature Composition: Co, Ni, Cu, Ti, Cr, Sn, Mo, Wc, W, Fe, Mn, among which the non-metallic elements in the metal pre-alloy powder account for less than 10% of the total mass.
3、 根据权利要求 1所述的金刚石串珠的制备方法， 其特征在于： 所述的金 刚石也可以是其它超硬材料， 例如硬质合金、 立方氮化硼、 碳化硼、 金刚石厚 膜、 碳化硅、 氧化铝以及它们的混合物。 3. The method for preparing diamond beads according to claim 1, characterized in that: the diamond can also be other superhard materials, such as cemented carbide, cubic boron nitride, boron carbide, diamond thick film, silicon carbide , alumina and their mixtures.
4、 根据权利要求 1所述的金刚石串珠的制备方法， 其特征在于： 所述的金 刚石也可以是表面镀钛或包裹有含有与碳易发生反应键合的元素的合金粉， 其 中键合元素例如钛、 铬、 钼、 钨、 硼、 硅及它们的混合物， 以提高金刚石在金 属胎体中的结合力， 提高工作层的使用寿命及效率。 4. The method for preparing diamond beads according to claim 1, characterized in that: the diamond can also be surface-coated with titanium or wrapped with alloy powder containing elements that are easily reactive and bonded with carbon, wherein the bonding elements For example, titanium, chromium, molybdenum, tungsten, boron, silicon and their mixtures are used to improve the bonding strength of diamond in the metal matrix and improve the service life and efficiency of the working layer.
5、 根据权利要求 1所述的金刚石串珠的制备方法， 其特征在于： 所述金属 预合金粉末与金刚石混合颗粒与有机结合剂的体积比为 75-50%: 25-50%, 其中 的有机结合剂包括热塑性树脂、 增塑剂及润滑剂， 一般选用聚乙烯、 石蜡、 硬 脂酸， 金刚石串珠粗坯的烧结温度为 700°C— 890°C。
5. The method for preparing diamond beads according to claim 1, characterized in that: the volume ratio of the metal pre-alloyed powder to the diamond mixed particles and the organic binder is 75-50%: 25-50%, wherein the organic The binding agent includes thermoplastic resin, plasticizer and lubricant. Polyethylene, paraffin wax and stearic acid are generally used. The sintering temperature of the diamond bead rough blank is 700°C-890°C.
6、 根据权利要求 1所述的金刚石串珠的制备方法， 其特征在于： 所述的预 热压成型工艺是将混合料 （包含金刚石、 有机结合剂、 金属预合金粉末）， 放入 钢模中在温度为 10°C— 250°C的中温热压机中热压成型，或在温度为 100°C— 250 °C的模腔中加压成型粗坯。 6. The method for preparing diamond beads according to claim 1, characterized in that: the preheating press forming process is to put the mixture (including diamond, organic binder, metal pre-alloy powder) into a steel mold Hot press forming in a medium temperature hot press with a temperature of 10°C-250°C, or press-forming the rough blank in a mold cavity with a temperature of 100°C-250°C.
7、根据权利要求 1至 5任一项所述的金刚石串珠的制备方法，其特征在于: 所述的金刚石串珠在高温炉中直接烧结成整体圆筒状串珠， 该串珠不需要串珠 基体作为支撑底层， 因此， 可使得串珠直径变小。 7. The method for preparing diamond beads according to any one of claims 1 to 5, characterized in that: the diamond beads are directly sintered in a high-temperature furnace into integral cylindrical beads, and the beads do not require a bead matrix as a support. The bottom layer, therefore, allows the bead diameter to be smaller.
8、 根据权利要求 1所述的金刚石串珠的制备方法， 其特征在于： 所述的金 刚石串珠粗坯， 在烧结后直径最小可达 lmm， 在制成金刚石绳锯时， 串珠外径 最佳为 3〜5mm。 8. The method for preparing diamond beads according to claim 1, characterized in that: the rough diamond bead blank has a minimum diameter of 1 mm after sintering, and when making a diamond wire saw, the outer diameter of the beads is preferably 3~5mm.
9、 根据权利要求 1所述的金刚石串珠的制备方法， 其特征在于： 所述的金 刚石串珠粗坯烧结后， 直径可达 5mm— 12mm。 9. The method for preparing diamond beads according to claim 1, characterized in that: after the rough diamond bead blank is sintered, the diameter can reach 5mm-12mm.
10、 根据权利要求 1至 6之一或 8或 9所述的金刚石串珠的制备方法， 其 特征在于： 所述的金刚石串珠可以一次性形成至少一种下面复杂的结构： 10. The preparation method of diamond beads according to one of claims 1 to 6 or 8 or 9, characterized in that: the diamond beads can form at least one of the following complex structures at one time:
1 ) 串珠两端可带有小孔； 1) The beads can have small holes at both ends;
2 ) 串珠两端可开槽； 2) Both ends of the beads can be slotted;
3 ) 串珠表面可形成螺紋状； 3) The surface of the beads can form a thread shape;
4 ) 串珠内腔可形成螺紋状； 4) The inner cavity of the beads can be formed into a thread shape;
5 ) 串珠底部可形成凸肩； 5) The bottom of the beads can form a convex shoulder;
6) 串珠两头可形成锥度。 6) The ends of the beads can be tapered.
11、 一种无基体支撑层的金刚石串珠绳锯， 其包含若干由权利要求 1至 10之一 所述的金刚石串珠的制备方法得到的串珠， 各串珠直接串于钢丝绳或钢性线条 上， 且在相邻串珠之间由橡塑材料包覆、 隔离固定。
11. A diamond bead wire saw without a matrix support layer, which contains a plurality of beads obtained by the preparation method of diamond beads according to one of claims 1 to 10, each bead is directly strung on a steel wire rope or a steel wire, and The adjacent beads are covered, isolated and fixed by rubber plastic material.
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| CN102825254A (en) * | 2012-09-05 | 2012-12-19 | 厦门致力金刚石科技股份有限公司 | Diamond bead string and manufacturing method thereof as well as rope saw without base body supporting layer |
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| CN102825254A (en) * | 2012-09-05 | 2012-12-19 | 厦门致力金刚石科技股份有限公司 | Diamond bead string and manufacturing method thereof as well as rope saw without base body supporting layer |
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