Design and Development of a Numerical Model and Study on Kinematic Analysis of a Circular Diamond Saw Blade for Ceramics
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2021-12-13 |
| Journal | International Journal for Research in Applied Science and Engineering Technology |
| Authors | N. Balasubramanyam |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: MPCVD Diamond for Super Abrasive Tooling
Section titled âTechnical Documentation & Analysis: MPCVD Diamond for Super Abrasive ToolingâThis documentation analyzes the research on the kinematic and structural optimization of circular diamond saw blades for ceramic cutting, highlighting how 6CCVDâs advanced MPCVD diamond materials and custom fabrication capabilities directly support and enhance this application.
Executive Summary
Section titled âExecutive Summaryâ- Application Focus: Design and kinematic analysis of segmented circular diamond saw blades (400 mm diameter) optimized for high-efficiency cutting of ceramics and hard stone.
- Methodology: Comprehensive numerical modeling (SolidWorks) followed by coupled thermal-structural Finite Element Analysis (FEA) using ANSYS 5.4 to study stress, deformation, and temperature distribution.
- Material Requirements: High-strength, high-density composite diamond segments (E=120 GPa, Density=8500 Kg/m3) manufactured via powder metallurgy are required to withstand extreme cutting forces.
- Optimization Achievement: Introduction of novel radial and curve annular slots (Conical Slot profile) successfully reduced total blade deformation (down to 0.208 mm) and mitigated vibration and thermal expansion issues.
- Kinematic Performance: Quantified cutting forces, demonstrating maximum tangential force (Ft) of 521 N and normal force (Fn) of 193 N at the highest tested cutting speed (30 m/s) and depth (25 mm).
- 6CCVD Value Proposition: 6CCVD provides high-purity MPCVD Polycrystalline Diamond (PCD) segments and custom metalization services, offering superior thermal management and mechanical stability compared to traditional sintered segments, crucial for replicating and extending this high-performance tooling research.
Technical Specifications
Section titled âTechnical SpecificationsâThe following hard data points were extracted from the FEA and kinematic analysis of the diamond saw blade:
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Blade Diameter | 400 | mm | Design specification |
| Segment Youngâs Modulus (E) | 120 | GPa | Composite Diamond Segment |
| Core Youngâs Modulus (E) | 210 | GPa | High-Strength Steel Core |
| Segment Density | 8500 | Kg/m3 | Composite Diamond Segment |
| Core Density | 7600 | Kg/m3 | High-Strength Steel Core |
| Max Circumferential Speed | 30 | m/s | Reference speed for force analysis |
| Max Depth of Cut (d) | 25 | mm | Maximum tested depth |
| Max Total Deformation (CR Slot) | 0.322 | mm | 8-Segment blade, Circular Slot |
| Min Total Deformation (CON Slot) | 0.208 | mm | 20-Segment blade, Conical Slot |
| Max Von Mises Stress (CR Slot) | 251.1 | MPa | 8-Segment blade, Circular Slot |
| Max Temperature (FEA) | 250 | °C | Coupled thermal-structural analysis |
| Max Tangential Force (Ft) | 521 | N | Vf=0.45 m/min, d=25 mm |
| Max Normal Force (Fn) | 193 | N | Vf=0.45 m/min, d=25 mm |
Key Methodologies
Section titled âKey MethodologiesâThe research utilized a combination of advanced design, material specification, and simulation techniques to optimize the diamond saw blade performance:
- Design and Modeling: Segmented circular diamond saw blades (400 mm diameter) with varying segment counts (8, 12, 16, 20) were designed using SolidWorks software.
- Material Specification: Diamond segments were modeled as composite parts created via powder metallurgy, incorporating diamond particles into a matrix to achieve high mechanical strength (E=120 GPa).
- Slot Profile Optimization: A novel radial slot model, including specific curve annular and conical slot profiles, was introduced and analyzed to mitigate common drawbacks such as noise, vibration, and lack of thermal expansion capacity.
- Finite Element Analysis (FEA): The models were imported into ANSYS 5.4, a commercial finite element program, for comprehensive analysis. The blade was divided into two parts (core and segments) using 8-noded isoperimetric shell elements (14004 elements, 43146 nodes).
- Coupled Thermal-Structural Analysis: FEA was performed to determine stress distribution, deformation, and temperature conveyance under load, confirming a maximum temperature of 250 °C.
- Kinematic Validation: The performance was validated by studying the relationship between cutting speed (Vf), depth of cut (d), tangential force (Ft), and normal force (Fn) at high peripheral velocities (up to 30 m/s).
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThis research demonstrates the critical need for high-performance, structurally stable diamond material capable of operating under extreme thermal and mechanical loads. 6CCVDâs MPCVD diamond solutions are ideally suited to replicate and advance this super abrasive tooling technology.
Applicable Materials
Section titled âApplicable MaterialsâThe study utilized composite diamond segments. 6CCVD offers superior alternatives and components:
- High-Purity Polycrystalline Diamond (PCD): 6CCVD specializes in MPCVD PCD wafers up to 125 mm in diameter. This material offers exceptional thermal conductivity and mechanical robustness, significantly exceeding the performance of traditional sintered segments, thereby minimizing the 250 °C thermal stress observed in the FEA.
- Single Crystal Diamond (SCD): For ultra-precision cutting applications or micro-tooling derived from this research, 6CCVD provides high-quality SCD plates (0.1 ”m to 500 ”m thick) with surface roughness Ra < 1 nm, ensuring minimal friction and wear.
Customization Potential
Section titled âCustomization PotentialâThe optimization of the saw blade relies heavily on precise geometry and robust segment bonding, areas where 6CCVD excels:
| Research Requirement | 6CCVD Capability | Technical Advantage |
|---|---|---|
| Custom Segment Dimensions | Custom plates/wafers up to 125 mm (PCD) and advanced laser cutting services. | We can precisely fabricate segment blanks matching the required dimensions (e.g., 8.00 x 4.00 mm) for optimal fit into the core slots. |
| High-Stress Bonding | Internal capability for custom metalization: Au, Pt, Pd, Ti, W, Cu. | Provides robust, high-temperature brazing interfaces necessary to secure segments against maximum forces (Ft=521 N) and thermal cycling. |
| Blade Core Substrates | Substrates available up to 10 mm thickness. | Provides high-quality diamond material for potential integration or cladding onto the steel core, enhancing overall stiffness and thermal dissipation. |
| Surface Finish | Polishing capability for PCD (Ra < 5 nm) and SCD (Ra < 1 nm). | Ensures minimal friction and improved chip evacuation, directly addressing the kinematic efficiency goals of the research. |
Engineering Support
Section titled âEngineering SupportâThe successful implementation of this design requires deep expertise in material science and structural mechanics.
- 6CCVDâs in-house PhD team can assist researchers and engineers with material selection for similar super abrasive diamond tooling projects.
- We offer consultation on optimizing diamond grade and geometry to manage stress distribution and minimize deformation, helping clients achieve or surpass the minimum 0.208 mm deformation results demonstrated by the conical slot design.
- We provide global shipping (DDU default, DDP available) to ensure rapid delivery of custom diamond materials worldwide.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
Abstract: Diamond tools are currently being used by an increasing number of architects, miners and construction engineers because they are faster and easier to use than older, more traditional instruments like sledge hammers and pneumatic and hydraulic jacks. Bridge and highway surfaces are cut with diamond asphalt and concrete cutting machines to provide for quick, clean, and easy section removal and replacement. The entire cost is reduced since diamond tools take less time and manpower The experiment is carried out to validate the performance of diamond saw blades by taking into consideration characteristics such as normal force, tangential force, cutting speed, cut depth, and peripheral velocity. In present exploration work we are introductory phase of plan conclusion of a jewel device cutting edge with various segmental like 8,12,16,20 corn meal by utilizing Solid works programming we are planning the apparatus cutting edge after that we are imported in Ansys Software for Analysis reason. Computing the necessary qualities for examination and estimations of earthenware tiles likewise are some other stone molecule. Another power model of cutting is presented and inferred numerical demonstrating for chip thickness. Identical chip thickness to coarseness space proportion is gotten from the new power model another outspread opening like profile is presented. Fragmented sort jewel saw sharp edge with the measurement of 400 mm and different portion, for example, 8, 12, 16 and 20 are planned in Solid works effectively. An examination study between existing roundabout outspread space and cone like opening is done to decide deformity, stress dispersion, vibration and temperature conveyance.