Techniques for Managing Endless Diamond Wire Saw Cutting Gaps

When equipped with a high-precision endless diamond wire saw cutting machine, users can determine cutting precision entirely, allowing for adjustable cutting speeds based on various materials and dimensions. Today, we explore the methods for controlling the gaps in endless diamond wire saw cutting.

On a cutting surface, such as a 245×245mm area, using a 0.25mm endless diamond wire saw typically results in gaps ranging from 0.27 to 0.5mm. Why mention 0.27 instead of 0.25? Endless diamond wire saws carry inherent tolerances; exceptionally precise cuts align with the wire saw diameter, representing the positive tolerance of the wire saw.

The gap’s variability depends on the curvature of the endless diamond wire saw within the work area. While the sample’s structure remains unchanged during cutting, the firmness of its fixation and the possibility of slight vibrations during the cutting process can impact the gap width.

1.Summarizing Gap Control Methods:

1.1Maintaining Constant Tension:

The fundamental principle behind endless diamond wire saw cutting machines is to maintain a constant tension within the working area, ensuring the production of high-precision workpieces.

 It is crucial to keep the section of endless diamond wire saw in contact with the workpiece under constant tension during the cutting process. Ideally, maintaining a straight line configuration throughout enhances cutting precision, bringing the gap closer to the diameter of the endless diamond wire saw.
Consequences of Inconsistent Tension:

In straight cutting processes, the absence of constant tension can lead to wire slackening due to the stretching motion during cutting, resulting in jittery cuts and the formation of new gaps that deviate from the intended path. This phenomenon is particularly pronounced at high speeds, causing significant deviations akin to washboard patterns and introducing errors in flatness.

1.2Workpiece Fixation:

The workpiece can be secured through clamping or adhesion. Our endless diamond wire saw cutting machine defaults to an adhesive method, offering stability to prevent workpiece displacement and ensure cutting accuracy. However, the clamping option is available upon user request.

1.3Maintaining Constant Tension in the Processing Area:

Mounted on the machine is a constant tension device that automatically tightens the endless diamond wire saw upon stretching. During cutting, users should monitor the wire closely. If bowing occurs, indicating that the cutting force of the wire saw lags behind the feed rate, adjustments to the cutting speed are necessary to rectify the issue.

1.4Enhancements in Automation:

Our endless diamond wire saw cutting machine incorporates an automatic curvature detection mechanism within the work area.

This feature automatically senses the wire saw’s curvature, feeding this information back to the CNC system for real-time adjustments of spindle speeds, feed rates, and other parameters, ensuring consistent tension cutting. Automatic tension detection proves more timely and effective compared to manual observation and adjustments, yielding superior results.

In conclusion

mastering the methods to control endless diamond wire saw cutting gaps revolves around securing the workpiece firmly and maintaining a constant tension within the processing area. These practices are instrumental in achieving high-precision cuts and optimal cutting outcomes