Process Parameters Analysis in Diamond Wire Saw Cutting NdFeB Magnet

At a Glance

Metadata	Details
Publication Date	2025-03-06
Journal	Materials
Authors	Cong Peng, Guanzheng Li, Xing-Chun Zhang, Yufei Gao
Institutions	Shandong University
Citations	3
Analysis	Full AI Review Included

Technical Documentation & Analysis: Precision Diamond Processing

6CCVD specializes in high-quality MPCVD diamond materials, providing Single Crystal Diamond (SCD), Polycrystalline Diamond (PCD), and Boron-Doped Diamond (BDD) solutions essential for advanced manufacturing, including the precision slicing techniques analyzed in this research.

Executive Summary

This research paper details the optimization of diamond wire saw (DWS) cutting parameters for Neodymium Iron Boron (NdFeB) magnets, a critical process in high-demand electronics and power machinery manufacturing.

Objective: Determine the optimal combination of workpiece feed rate ($V_w$), wire speed ($V_s$), and workpiece size ($L$) to minimize surface roughness (Ra) and waviness (Wa/PV).
Methodology: A three-factor, five-level orthogonal experiment was conducted using industrial production parameters.
Key Finding: Workpiece feed rate ($V_w$) is the dominant factor influencing surface quality (Ra, Wa, and PV).
Optimal Parameters: The best surface quality was achieved at a low feed rate (0.1 mm·min⁻¹), high wire speed (1600 m·min⁻¹), and small workpiece size (10 mm).
Achieved Quality: The optimal combination yielded an ultra-smooth surface roughness of Ra = 0.433 µm and waviness of Wa = 0.037 µm.
Relevance to 6CCVD: The success of DWS relies on high-performance diamond abrasives and the resulting NdFeB slices are integrated into devices requiring advanced materials like SCD heat spreaders or BDD electrodes.

Technical Specifications

The following hard data points were extracted from the orthogonal experiment and optimal results:

Parameter	Value	Unit	Context
Optimal Surface Roughness (Ra)	0.433	µm	Achieved under optimal parameters
Optimal Surface Waviness (Wa)	0.037	µm	Achieved under optimal parameters
Optimal Workpiece Feed Rate (Vw)	0.1	mm·min⁻¹	Lowest tested level (A1)
Optimal Wire Speed (Vs)	1600	m·min⁻¹	Highest tested level (B5)
Optimal Workpiece Size (L)	10	mm	Smallest tested level (C1)
PV Regression Model (Non-LaTeX)	PV = 0.747 * V_s^-0.342 * V_w^0.546 * L^0.109	N/A	Mathematical model for Peak-Valley waviness
Diamond Wire Core Diameter	220	µm	Parameter of the diamond wire used
Abrasive Size	70-85	µm	Nickel-coated diamond abrasive
Abrasive Density	15-20	grits·mm⁻¹	Abrasive distribution density

Key Methodologies

The experiment utilized a high-speed diamond wire saw to analyze the impact of process parameters on NdFeB surface quality.

Equipment: Diamond single-wire cutting machine (SH300).
Workpiece Material: N35-sintered NdFeB rectangular magnets.
Workpiece Dimensions: Cut surface L x 20 mm; slice thickness set to 1 mm.
Cutting Fluid: Tap water was used for cooling and lubrication during the sawing process.
Experimental Design: A three-factor (Feed Rate, Wire Speed, Workpiece Size) and five-level orthogonal experiment was conducted, totaling 25 parameter combinations.
Parameter Ranges Tested:
- Feed Rate ($V_w$): 0.1 to 1.3 mm·min⁻¹
- Wire Speed ($V_s$): 800 to 1600 m·min⁻¹
- Workpiece Size ($L$): 10 to 50 mm
Measurement: Surface quality (Ra, Wa, PV) was evaluated using a laser confocal microscope (Keyence VK-X200K).

6CCVD Solutions & Capabilities

This research underscores the critical role of high-quality diamond materials in achieving superior surface finish and precision when processing hard, brittle materials like NdFeB. 6CCVD provides the foundational MPCVD diamond materials necessary for both the cutting tools and the advanced electronic components resulting from this manufacturing process.

Applicable Materials for Replication and Extension

To replicate or extend this research—either by manufacturing superior cutting tools or integrating diamond into the final NdFeB-based devices (e.g., power electronics, sensors)—6CCVD recommends the following materials:

6CCVD Material	Application Relevance	Key Technical Specifications
High-Purity Polycrystalline Diamond (PCD)	Tool Manufacturing: Ideal for creating high-wear, high-efficiency cutting tools, dies, and wire drawing components used in DWS machines.	Custom dimensions up to 125mm diameter. Thickness up to 500 µm. Excellent wear resistance.
Optical Grade Single Crystal Diamond (SCD)	High-Precision Substrates/Windows: Used in high-power laser systems or sensors where the NdFeB magnets are integrated. SCD offers unparalleled thermal management.	Polishing to Ra < 1 nm. Thickness range: 0.1 µm to 500 µm. Highest thermal conductivity (>2000 W/mK).
Boron-Doped Diamond (BDD)	Electroplating/Sensing: NdFeB slices require subsequent electroplating (as noted in the paper). BDD electrodes offer superior chemical stability and efficiency for advanced plating or electrochemical sensing applications.	Highly conductive material. Available in custom plates and wafers.

Customization Potential for Advanced Research

The paper highlights the need for precise control over material dimensions and surface characteristics (Ra, Wa, PV). 6CCVD’s custom capabilities directly address these requirements:

Custom Dimensions: We supply SCD and PCD plates/wafers in custom sizes, including large-area PCD up to 125mm, allowing researchers to test various workpiece sizes ($L$) or manufacture large-scale tools.
Precision Polishing: While the paper achieved Ra = 0.433 µm on NdFeB, 6CCVD can provide SCD substrates polished to an industry-leading Ra < 1 nm and inch-size PCD polished to Ra < 5 nm, crucial for high-fidelity optical or thermal applications.
Advanced Metalization: For integrating diamond materials into electronic or magnetic assemblies, 6CCVD offers internal metalization services, including Au, Pt, Pd, Ti, W, and Cu layers, ensuring robust electrical and thermal contacts.

Engineering Support

The optimization of complex processes, such as minimizing waviness (PV) using the derived regression model (PV = 0.747 * V_s^-0.342 * V_w^0.546 * L^0.109), requires deep material science expertise. 6CCVD’s in-house PhD team specializes in the properties and applications of MPCVD diamond. We can assist engineers and scientists with material selection, design optimization, and integration strategies for similar precision slicing, thermal management, or electrochemical projects.

For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly. We offer global shipping (DDU default, DDP available) to support your research worldwide.

View Original Abstract

Neodymium iron boron (NdFeB) magnetic materials are widely used in fields such as electronics, medical devices, power machinery, and hardware machinery. This paper conducted a three-factor and five-level orthogonal experiment on diamond wire saw cutting NdFeB to determine the influence degree of key factors such as workpiece feed rate, diamond wire speed, and workpiece processed size on the surface roughness Ra and waviness Wa of NdFeB slices. Further analysis was conducted on the influence of various parameters on the PV value (peak valley difference) of the waviness profile curve of the sawed surface. Finally, slicing processing was carried out under optimized process parameter combinations. The research results indicate that the primary and secondary order of process parameters affecting surface roughness Ra and waviness Wa is workpiece feed rate, wire speed, and sawed workpiece size, and the influence on the waviness PV value also shows a consistent trend. The optimal combination of processing parameters is workpiece feed rate of 0.1 mm·min−1, wire speed of 1600 m·min−1, and workpiece size of 10 mm. The obtained surface roughness Ra is 0.433 μm and the waviness Wa is 0.037 μm, respectively. The regression mathematical model for the waviness PV value is PV = 0.747 × vs−0.342 × vw0.546 × L0.109. The research results of this paper provide an experimental basis and guidance for optimizing process parameters of sawing NdFeB.

Tech Support

Original Source

DOI: https://doi.org/10.3390/ma18051173

References

2024 - Interpretable Prediction of Remanence in Sintered NdFeB through Machine Learning Strategy [Crossref]
2023 - Structure and Corrosion Resistance Characteristics of ZnAl/EP Coating on Bonded NdFeB Magnet [Crossref]
2024 - Low Temperature Machining Advantages for Sintered NdFeB Magnets: A Comparative Experimental Study of WAWJ with Laser and WEDM
2014 - Experimental Investigation of Wire Electrical Discharge Machining of NdFeB Permanent Magnets with an RC-Type Machine [Crossref]
2022 - Experimental Study on Magnetic Field Assisted WEDM Machining Sintered NdFeB
2017 - Research on High Efficiency and Low Loss Cutting of NdFeB Permanent Magnet Material by WEDM
2023 - Effect of Fiber Laser Cutting Technology on Sintered NdFeB Magnetic Performance
2020 - Simulation Analysis of Temperature Field of Laser Cut Ndfeb Magnetic Material
2019 - Study on the Effect of Sintered NdFeB Laser Cutting Quality Technology
2024 - Development of Microencapsulated Phase Change Material Slurry for Diamond Wire Sawing Silicon Wafer and Its Effect on Cutting Quality [Crossref]