Establishment And Experimental Study Of Fracture Prediction Model Of Diamond Wire Saw

With the continuous development of China's manufacturing industry and the improvement of engineering technology,brittle and hard materials are widely used in related fields due to their high hardness,high temperature resistance,corrosion resistance and wear resistance.Diamond wire sawing technology is widely used in the slicing process of brittle and hard materials such as sapphire,monocrystalline silicon and ceramics.It has the advantages of wide processing range,high cutting efficiency and low surface loss.Previous studies have shown that during the cutting process,the fracture of the saw wire not only reduces the surface quality of the workpiece,affects the processing efficiency,and even damages the workpiece.In order to further improve the surface quality of the slice and improve the processing efficiency,the prediction of the fracture of diamond saw wire is studied.In order to deeply analyze the influence of failure mode and process parameters of diamond saw wire on the fracture of saw wire and predict the fracture of saw wire,the fracture process of diamond saw wire was studied by combining simulation and experiment.The main work is as follows,Firstly,the micro fracture model and macro fracture model of diamond saw wire are established.The fracture process and fracture form of saw wire were analyzed by micro fracture model.The tensile fracture model of saw wire was established,and the influence of process parameters on the fracture of saw wire was analyzed.The relationship between saw wire deflection angle and process parameters was studied to provide theoretical guidance for subsequent work.Secondly,the fracture process of diamond saw wire was simulated.The stress-strain curve and ultimate tensile strength of saw wire were obtained by tensile test.The three-dimensional simulation model of saw wire fracture was established,and the surface morphology of saw wire was analyzed.The fracture process and fracture form of saw wire were obtained.The consistency of simulation results and experimental results was verified by comparing stress and strain with fracture.The three-dimensional model of wire saw fracture in the process of wire saw cutting is established.Through the analysis of the surface morphology of the wire saw,the fracture process and fracture area of the wire saw are obtained.The variation law of tension and its influencing factors in the process of wire saw cutting are analyzed,which provides guidance for experimental research.In addition,the fracture experiment of diamond saw wire was studied.Based on the reciprocating wire saw cutting machine tool,the single factor experiments of wire speed,workpiece feed speed and sawing length were designed to study the influence of process parameters on the fracture of saw wire.The surface morphology,tension and tension fluctuation of saw wire,the deflection angle of saw wire and the life of saw wire were analyzed to reveal the influence of process parameters on the fracture of saw wire,and provide sample data and experimental guidance for the fracture prediction of diamond wire saw.Finally,the fracture of diamond saw wire is predicted.The multi-layer perceptron(MLP)neural network model is built,and the gradient descent algorithm and activation function are combined to verify.The optimal parameters are selected to optimize the neural network model to realize the prediction of saw wire life.Based on Python and Open CV vision library,a saw blade recognition system is built to identify the saw blade position in the cutting process,and the saw blade angle under different process parameters is measured and compared with the experimental results.According to the above measures,the fracture prediction of diamond saw wire is realized.