Please send us your inquiry about the customization of other furnace types or related questions about vacuum furnace. We will reply you immediately. Thank you.
Downloads
All documents in the overview
News & Press
All news at a glance
Request
Send us a message
Email: contact@vacfurnace.com
Tel : +86-21-50878190
Wechat : 2210154395
Address: NO.1299, XinJinQiao Road, Pudong New Area, Shanghai, China.
Ultra-thin PCD circular saw blade vacuum brazing process
Ultra-thin PCD circular saw blade is a high-efficiency cutting tool. It has been widely used in various industries such as furniture, lumber making, construction, decoration, decoration, non-ferrous metallurgy, etc. It can be used to process various soft and hard natural woods, particleboards, plywood, etc. Fiber board, laminated board and other man-made panels, as well as aluminum alloy profiles, plastic, plastic steel doors and windows, organic glass, fiberglass and other non-metallic materials.
Ultra-thin PCD circular saw blades are particularly suitable for cutting laminate flooring. In recent years, the laminate flooring processing industry has developed rapidly. Since all the panel cutting processes of laminate flooring processing use circular saw blades, the market demand for circular saw blades is considerable. In the past, laminate flooring mostly used carbide circular saw blades for panel cutting. Since there is a layer of Al2O3, a wear-resistant layer, on the surface of laminate flooring, its hardness is extremely high, and the wear on the carbide circular saw blades during processing is considerable. A carbide saw blade can usually only process dozens of large plates before the cutting edge becomes dull and must be sharpened. The PCD circular saw blades developed in recent years have the advantages of high cutting speed, good wear resistance, low noise, high efficiency, good processing quality, high smoothness of the processed surface, and no edge chipping of the board. An ultra-thin PCD circular saw blade can It can process 8,000 to 10,000 large plates, and its durability is hundreds of times that of carbide saw blades. Therefore, it is gradually replacing traditional carbide saw blades, and its market prospects are very broad.
1. Main technical parameters of ultra-thin PCD circular saw blades
Saw blade diameter: φ200 ~ φ350mm; number of teeth: 40 ~ 80Z (PCD); tooth width: 1.8 ~ 2.5mn; base thickness: 1.4 ~ 2mm; rotation speed: 3800 ~ 5000r/min; cutting thickness: 20 ~ 60mm.
2. Selection of saw blade base material
The matrix is the carrier of the PCD blade. Since the base thickness of PCD round slices is very thin (1.5~1.8mm) but the diameter is large (φ200~φ350mm), the linear speed during cutting can reach 50~100m/s, and the cutting thickness can reach more than 60mm, so the saw blade is used During the process, it has to withstand high temperatures, strong impact, extrusion, distortion, friction, etc., and the use environment is very harsh. A large amount of industrial adhesive in the base material of the saw blade is easily melted by heat and adheres to the PCD blade, increasing resistance and affecting processing. In severe cases, it may cause base deformation or even tooth back fracture. Therefore, the requirements for the mechanical properties of the saw blade base are very high. It is necessary to comprehensively consider the flatness, rigidity, toughness and other aspects to correctly select the base material. In addition, the deformation of the base body after welding is required to be as small as possible. Generally speaking, the hardness of the saw blade base is 42 ~ 48HRC. It is not too high or too low. Materials such as 75Crl and 65Mn are more suitable as saw blade base materials.
3.Selection of PCD blade model
The choice of PCD blade for saw blades should match the material of the workpiece being processed. Because the wear resistance and strength of different types of PCD blades are quite different, only by correctly selecting the appropriate PCD blade according to the workpiece material can an ideal processing effect be achieved.
4. Vacuum brazing of PCD saw blades
Low-temperature vacuum brazing technology should be used and the welding temperature should be strictly controlled. The ultra-thin PCD circular saw blade has narrow teeth and a small welding surface, making it difficult to weld firmly and has higher requirements for silver solder and flux. After vacuum brazing, stress relief treatment should be performed to reduce deformation.
5. Cutting angle and tooth profile
The cutting angle and tooth profile of the PCD circular saw blade directly affect the processing quality and life of the saw blade. The commonly used cutting angles of PCD circular saw blades are: rake angle y: 5~15°; relief angle α: 10~18°; side relief angle 3~5°. The tooth types of PCD circular saw blades include flat teeth, left helical teeth, right helical teeth, trapezoidal teeth, arc teeth, triangular teeth, conical teeth, etc. (see Figure 1). These tooth types usually need to be used in combination. Generally speaking, the tooth shapes of two adjacent teeth of PCD circular saw blades are different, and the tooth heights are also different. For example, in a combination of flat teeth and trapezoidal teeth, the trapezoidal teeth are 0.2~0.3mm higher than the flat teeth. Therefore, the optimal cutting angle and tooth profile combination must be selected based on different machine tools, different materials to be processed, and different requirements of different customers.
Circle 1 PCD saw blade tooth profile
6. Sharpening of PCD saw blades
PCD saw blade sharpening is a very critical process. The accuracy and dimensional tolerance of the saw blade tooth profile are strict: the external tooth tip runout ±
0.015mm; side runout ±0.025mm; runout of two adjacent teeth ±0.01mm, roughness Ra<0.3pm. Mechanical sharpening simply cannot meet the above requirements, and special PCD CNC EDM equipment must be used for processing. Generally, the two sides are processed first, and then the rear corners are processed. Two methods, cylindrical discharge and end face discharge, can be used. Since the saw blade has many and dense teeth (40 ~ 80Z), interference must be prevented during processing, and the tooth profile must be sharpened symmetrically with respect to the base. Otherwise, uneven force on both sides may easily cause the PCD circular saw blade to wear out too quickly and reduce its service life.
The PCD vacuum brazing furnace produced by SIMUWU Company uses light radiation heating to greatly improve the heating efficiency. The device is small, convenient, intuitive and easy to operate. Especially suitable for the industry characteristics of super hard tools. Using a small vacuum sealing method, heating and cooling in a vacuum state, personnel without operating experience can easily perform welding operations, which greatly improves welding quality, welding strength and stability.
Main technical parameters
Learn More:
Vacuum annealing process of titanium alloy
Heat treatment process for wide and thick plates
Vacuum Hardening and Vacuum Tempering Heat Treatment for Metal Parts