Experimental Investigation On Forming-Cutting Aluminum Alloy Thick Plate With Endless Brazing Diamond Wire Saw

The conceive of manufacturing the endless diamond wire saw by using high-frequency induction brazing process, and then with which shape-cutting the aluminum alloy thick plate was developed in the paper. Centering on the conception, The main research completed in this paper include:1.The cutting test platform was established. Carpentry band saw machine was modified into diamond wire saw cutting machine, with the constant feeding tension and the speed of endless diamond wire saw between 4.7-13.5 m/s. The machine basically meet the requirements of the tests.2.The endless diamond wire saw was successfully manufactured with the length of 2000mm and the diameter of 1.2 mm. the appropriate metal wires, brazing alloy and the process was selected according to the requirements of the induction brazing diamond wire saw process in the argon protection device; The endless diamond wire saw was made by TIG with the perimeter 1720 mm ,which has a well bonded welding joint.3.The cutting tests were carried out with manufactured endless diamond wire saw on cutting machine. The results demonstrate: the efficiency increasing and the curvature radius reducing when the cutting force increased; the curvature radius increasing and the efficiency raising when the cutting speed improved; the cutting efficiency improving when the diamond size increased. and when the aluminum alloy thick plate can be forming-cutting by using endless diamond wire saw when pre-tightening force,cutting force and cutting speed are proper.4.The cutting mechanism and failure pattern of the diamond wire saw were researched. The single particle cutting mode was established. The tests and the theories research turned out that the aluminum alloy chips were zonal; the main failure pattern of the diamond wire saw were abrasive breakage and fatigue fracture. The methods of improving the diamond wire saw life was proposed.