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Improved Cutting Performance of Diamond Beads by Means of Innovative

Shape

2nd International Industrial Diamond Conference

Roma, 19-20 April 2007

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Fabrication technologies

Hot pressing: advantages and drawbacks

Electroplating: advantages and drawbacks

Pressureless sintering: advantages and drawbacks

HIP: advantages and drawbacks

New technology

Lower costs

Higher performances

Conclusions

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Traditional Technologies

Electroplated toolHot pressing

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Sintering furnaces set

Traditional Technologies

Hot isostatic pressing

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Powder Binder

Feedstock

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Injection Moulding

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Metal Powder

Temporary binder

Backbone binder

Debinding

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Pressureless sintering

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Very complicate shapes are possible

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Cobalt UF WC Diamond 40/50

mesh Binder

Weight % 77.2 9.0 2.6 11.2

Wax 1 Wax 2 Polyethylene Stearic acid Weight % 10 69 20 1

Experimental

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Green part Sintered beads

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Beads after brazing Beads during cut

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8

9

10

11

12

13

14

15

16

17

7.588.599.51010.51111.5

Bead diameter

Cu

ttin

g p

res

su

re (

A.U

.)

Traditional BeadNew Geometry

Theory

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4.00

5.00

6.00

7.00

8.00

9.00

10.00

11.00

12.00

0 200 400 600 800 1000 1200 1400

Square meters of cut

Bea

d D

iam

eter

, mm

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

2.20

Feed

Rat

e, m

/h

Diameter, Traditional Diameter, Double Bulge Feed Rate, Traditional Feed Rate, Double Bulge

Practice

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A general analysis of the costs in any cutting operation leads to the following expression:

Economical features

Co Cost of labour (€/min) Tt Cutting time for one cut (min) Ttc Down time for substituting the wire (min) Sm Depreciation cost of the equipment (€/min) Cm Operating cost of the equipment (€/min) Ct Cost of the wire (€) nt Number of wires necessary for one cut

C=(Co+Sm+Cm)Tt + Ctnt + (Co+Sm)Ttcnt

F

111

nnt

tt FFTT

Tn

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0

0.5

1

1.5

2

2.5

3

3.5

0 10 20 30 40 50 60 70 80 90 100

Feed rate, A.U.

Cos

t pe

r pa

rt, A

.U.

Machine cost

Tool cost

Total cost

A cost saving higher than 15% is possible

Conventional Double Bulge

Total surface of the cut (m2) 5000 5000 Number of wires for the cut 4 5 Time necessary for the cut (h) 1666 1351 Average feed rate (m/h) 1 1.23 Relative cost of the cut 1 0.84

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•A new process based on Diamond Injection Moulding has been developed and patented. The process allows to produce tools with intricate geometries not possible to make so far

•With the new process a innovative diamond bead has been produced and tested in a full scale plant. The new double bulge geometry allows the wire to cut with a higher speed, that determines a cost saving higher than 15% in spite of the slightly reduced wire lifetime

Conclusions