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Thermal simulation of the continuous pulse discharge for electro-spark deposition diamond wire saw

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Abstract

Due to their excellent physical and mechanical properties, third-generation super-hard semiconductor materials (such as SiC, GaN) are used widely in the field of microelectronics. However, due to its ultra-high hardness, the machining is very difficult, which has become the bottleneck of its development. Slicing is the first machining procedure that directly affects the subsequent process. Fixed abrasive diamond wire saw (DWS) has been widely used in cutting hard and brittle materials. However, the diamond abrasives are attached to a core wire by resin or electroplated, that slicing super hard crystals is very difficult and inefficient. In order to improve the slicing efficiency, it is necessary to improve the holding strength and wear resistance of the DWS. The electro-spark deposition (ESD) process can deposit electrode materials on the substrate under the condition of low heat input to achieve metallurgical bonding between metal materials. And it can improve the wear resistance, corrosion resistance, and repair the size of the workpiece. It has been widely used in the field of surface modification engineering. It can effectively improve the bonding strength of the abrasive grains, and the sawing ability of the wire saw to make the consolidated DWS by the ESD process. Due to its thin matrix and poor thermal properties, the saw wire is easy to burning or even breaking in the manufacturing process. At present, the selection of pulse interval time in the ESD process is generally determined by the duty factor. However, the pulse interval time selected according to duty factor is difficult to meet the heat dissipation requirements of electro-spark deposition DWS (ESDDWS). In this paper, two kinds of motion modes of ESDDWS manufacturing are put forward, according to the manufacturing characteristics of ESDDWS. The boundary conditions of the continuous pulse discharge of ESDDWS are established. The thermal simulations of continuous pulse discharge of ESDDWS under two motion modes are analyzed. According to the simulation results, the basis of the value of pulse interval in the ESDDWS process is put forward. The effect of pulse interval time on the mechanical performance of the wire saw is analyzed experimentally. The results show that selected the discharge interval time base on the simulation results can ensure the continuous production of the ESDDWS.

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The data and materials supporting the results of this article are included within the article.

Abbreviations

c :

Specific heat capacity

h :

Convection heat coefficient

I :

Discharge current

k :

Thermal conductivity

m :

Number of discharge

q 0 :

Maximum heat flux

R :

The radius of the plasma channel

R j :

The radius of the saw wire

r :

Coordinates of cylindrical work domain

T :

Temperature

T 0 :

Environment temperature

t :

Time

t on :

Pulse duration time

t off :

Pulse interval time

z :

Coordinates of cylindrical work domain

β :

The angle between the incident direction of the heat flow and the normal direction at a point on the core wire surface

θ :

Coordinates of cylindrical work domain

ρ :

Density

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Funding

This work is financially supported by the National Natural Science Foundation of China (No. 51775317) and the Key Research and Development Program of Shandong Province, China (No. 2019JZZY020209)

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Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Chengyun Li, Peiqi Ge & Wenbo Bi

  2. Key Laboratory of High-Efficiency and Clean Mechanical Manufacture at Shandong University, Ministry of Education, Jinan, 250061, China

    Peiqi Ge

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  1. Chengyun Li
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  2. Peiqi Ge
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Contributions

Chengyun Li is the executor of article writing and experiment operation. Peiqi Ge contributed to the conception of the work. Wenbo Bi contributed to the experiment preparation.

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Correspondence to Peiqi Ge.

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Li, C., Ge, P. & Bi, W. Thermal simulation of the continuous pulse discharge for electro-spark deposition diamond wire saw. Int J Adv Manuf Technol 119, 2923–2933 (2022). https://doi.org/10.1007/s00170-021-08444-x

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