1 Introduction
Diamond circular saw blades are the most expensive tools in diamond tools, accounting for more than 95% of the total diamond tool material consumption. In recent years, China has carried out a lot of research on optimizing the formula of diamond circular saw blade, which has significantly improved the sawing performance of diamond circular saw blade, greatly reduced the cost of the cutter head, and improved the competitiveness of domestic saw blade in the domestic and foreign markets. With the increasing application range of diamond circular saw blades, the processing objects are becoming more and more complex. At present, in addition to the general wear resistance and sharpness requirements of saw blades, they are also adapted to the materials to be processed (such as various marbles and granites). , reinforced concrete, asphalt pavement, etc., processing conditions (such as dry cutting, wet cutting, sawing ultra-thin plates, high-precision plates, etc.) and environmental requirements (such as noise, sewage, etc.) put forward higher requirements, these are The design and manufacture of diamond circular saw blades poses new challenges. It is far from enough to improve the performance of saw blades by optimizing the formula of the block, and more progress and breakthroughs must be made in improving the structure of the saw blade. In recent years, various new saw blade bases and sawtooth structures developed and used at home and abroad (such as saw blade base open air hole slots or damped materials, sandwiched sandwich teeth forming serrated concave teeth, multiple fine teeth, radially extending teeth) , carbide tips, etc.) to improve sawing friction and cooling conditions, improve saw blade sharpness and cutting stability, prevent serration slip, prevent side wear, adapt to soft and hard mixed material processing, avoid tooth loss, save tool materials It has played an important role in making full use of sawtooth materials and reducing sawing noise. It has been proved that improving the saw blade base and sawtooth structure is one of the important ways to improve the sawing effect.
However, at present, there is still a lack of in-depth systematic theoretical analysis of the influence of various base and sawtooth structures on the force, rigidity, deformation, stress distribution, friction and noise of the saw blade. Therefore, the theoretical basis for improving the technical scheme of the base and sawtooth structure is still proposed. insufficient. This paper introduces the research and application results of improving the saw blade base and sawtooth structure at home and abroad, analyzes the characteristics, production value and existing problems of various sawtooth structures, and puts forward the theoretical problems and techniques involved in the study of saw blade base and sawtooth structure. prospect.
2 Characteristic analysis of saw blade base and sawtooth structure
2.1 Anti-side wear base and serrated structure During the sawing process, the saw blade runs at high speed, and the saw blade base and the debris flow cause friction and wear. Since the radial wear of the segment is inconsistent with the lateral wear, when the working layer of the segment is consumed, the friction between the saw blade base and the cuttings is increased, resulting in a “clip sawâ€, which will cause wear and deformation of the saw blade base. , reducing the number of times the substrate can be reused. To this end, the following measures to protect the substrate can be taken. 1) The hard particles are welded by the electric welding method on the saw blade base in a circumferential direction and distributed in a radial direction. The method can reduce the wear of the cuttings flow on the side of the base body, but will increase the manufacturing cost of the base body and the difficulty of correcting the deformation of the base body.
A low-temperature spray method is used to spray a layer of WC-Co as a main component on the side of the saw blade substrate. This method not only prevents side wear but also increases the rigidity of the saw blade. If the concrete surface is sawed with a diamond circular saw blade with an outer diameter of Ø323mm (saw blade speed 2400r/min, depth of cut 60mm, feed rate 3m/min), the service life of the saw blade can be increased from 2899m to 4500m after spraying the spray layer. The selection of the best spray coating process, layer thickness, spray area, etc. is the key to the application of this technology. 5) The block uses a staggered distribution tank, the depth of the tank is 2/3 of the thickness of the block, and the radial depth reaches the welded layer. The contact surface is a continuous segmentation pattern during sawing. This technology is beneficial to cooling lubrication, can improve the chip removal ability, and reduce the friction and distortion of the base block to the base.
2.2 Improvement of stress state, friction and cooling conditions of the substrate and sawtooth structure By analyzing the stress state and frictional cooling conditions of the saw blade, the base and the sawtooth structure can be reasonably improved, which can effectively improve the mechanical deformation of the base and the frictional cooling conditions of the sawtooth, and delay the failure of the substrate. The time limit improves the wear resistance and sharpness of the saw blade, saves tool materials and reduces processing costs.
1) HDJerro uses the finite element method to analyze the stress of the single-tooth sawing of a common section, the sawing of a tooth, the sawing of a tooth, and the simultaneous cutting of two teeth. When the diameter of the saw blade is Ø200mm, the depth of cut is 2mm, the thickness of the saw blade is 1.8mm, the groove width is 7mm, and the distance from the bottom hole of the sink to the outer circumference of the saw blade is Sh=8.5mm, the design has a better comprehensive processing effect as shown in Fig. 6. Sink structure. The structural parameters of the water tank are: γ=10°, r=3.5 mm, ψ=5°, Ø=5°. This paper reveals the feasibility of applying the finite element method to analyze the force state of the saw blade, but the breadth and depth of the force analysis need to be further improved.
2) In order to improve the thermal stress state of the saw blade during the sawing process, the radial extending groove can be increased at even intervals on the substrate to meet the thermal expansion and contraction of the substrate, and the deformation of the substrate due to thermal stress is reduced.
3) In order to improve the friction condition and stress condition of the serrated top and the flank, a "back" shaped tooth, an "H" shaped tooth, a "concave" shaped tooth and the like can be formed on the top surface of the tooth. Segmented homogenous sandwiches with different end shapes and teeth and sandwiches that are widely used today.
The "return", "H" and "concave" teeth forming the concave surface of the tooth surface reduce the contact area between the tooth top and the processing material, improve the pressure state of the flank, and the friction and heat generation can be significantly reduced. The sharpness of the cutter head increases. At the same time, because the rock corresponding to the concave part in the block is often thin and brittle, the rock is naturally broken under the action of surrounding impact energy, thereby saving the material of the working layer of the block.
The non-homogeneous sandwich tooth diagram can reduce the tooth surface friction contact area of ​​the tooth type, as well as "L" type teeth, step type teeth, side grooved teeth, etc., such as NED Company of Japan, Osaka Diamond Company of Japan, WihelmLeiritz Company of Germany, etc. The tooth profile is used on large diameter saw blades from Ø1000 to 5000 mm. For small-diameter saw blades, the helical tooth type shown in Fig. 12 can be used. This type of tooth shape facilitates the introduction of the cooling medium, and the gradual change of the cutting length of the cutting piece can slow down the impact force. The key to the successful application of this method is the rational selection of the helix angle, the tooth profile and the control of the cold press forming process.
4) In order to increase the density of the cooling trough without causing insufficient rigidity of the saw blade due to excessive steel base tank, multiple serrations can be used. The outer edge of the segment is slightly lower than the inner groove. When the outer tooth is worn out, the inner tooth can be cut like a new tooth. Due to the shortening and delamination of the tooth length, the friction cooling condition can be improved, the sawtooth slip can be avoided, the sharpness of the saw blade and the smoothness of the cutting can be increased, and the effect of the tool material can be fully utilized. This effect is compared with the "small block length" studied by domestic scholars. The conclusion is that the total power consumption of the saw blade is smaller when it is cut. However, such a block needs to be produced by cold press forming, which increases the cost of mold making and the difficulty of welding.
3 Conclusion
This paper introduces the characteristics, production value and existing problems of saw blade structure base and sawtooth structure which are anti-side wear, anti-stress deformation and improved cooling performance at home and abroad. In the following articles, the structural characteristics, production value and existing problems of dry cutting, impact resistant and low noise saw blades will be analyzed and discussed, and the technical problems involved in studying the saw blade base and sawtooth structure will be proposed. The corresponding theoretical method.
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