GB/T 30470-2026Superabrasive products - Diamond wire saws (English PDF)

5.1 Structural Type and Code

5.1.1 The wire saw mainly consists of three parts. a steel wire rope, diamond beads (hereinafter referred to as "beads"), and fixing materials. Its structure is shown in Figure 1 and Figure 2. As shown in Figure 3.

5.1.2 The beads are mainly composed of two parts. a steel substrate and an abrasive layer, as shown in Figure 4.

5.1.3 The manufacturing method and code of the beaded abrasive layer are shown in Table 2.

5.1.4 The types and codes of materials for fixing beads are shown in Table 3.

5.2 Size Codes and Dimensions

5.2.1 Size Code The dimension codes for each part of the wire saw are shown in Table 4, and the dimension markings are shown in Figures 1, 2, 3 and 4 respectively.

5.2.2 Dimensions and Specifications The dimensions and specifications of the wire saw are shown in Table 5.

7.4 Appearance

7.4.1 For wire saws that use rubber or plastic to fix the beads, the surface of the fixing material should not have blistering, cracks or other defects.

7.4.2 For wire saws using spring-loaded beaded cables, the wire rope should be free of any damage after assembly. The spring ends should be closed and wound, and each end should be ground. smooth.

7.4.3 The surface of the beads should not have rust spots or oxide layers.

7.4.4 The diamond particles on the working surface of the beaded surface should be exposed and evenly distributed.

7.4.5 The working surface of the sintered beads shall be free from defects such as chipped edges, chipped corners, cracks, gaps, and dents.

7.4.6 The working surfaces of brazed and electroplated beads should be free from defects such as peeling and blistering.

7.5 Basic Dimensional Limit Deviations The basic dimensional tolerances of the wire saw should conform to the specifications in Table 6. Table

6 Basic Dimensional Limit Deviations The unit is millimeters. Basic dimensional tolerances D ±0.2 0.005L <=15 (Difference in length between closed-loop wire saws used in the same group) L2 0.2 -0.3

7.6 Bond strength between abrasive layer and steel substrate For beads manufactured by sintering, the bonding strength between the abrasive layer and the steel substrate, expressed as shear stress (tau1), should not be less than 60 MPa.

7.7 Fixing strength of beads and wire rope A wire saw that uses rubber, plastic, plastic and spring, or rubber and spring to fix the beads; the fixing strength between the beads and the wire rope is measured by shear stress. (tau2) indicates that it should not be less than 10 MPa.

7.8 Fixing strength between the pressure ring and the wire rope The fixing strength between the spring wire saw clamping ring and the wire rope should not be less than 20% of the minimum breaking tensile strength of the wire rope.

7.9 Connection strength of wire saw joints The connection strength of a conventional wire saw joint should not be less than 30% of the minimum breaking tensile strength of the wire rope; the connection strength of a closed-loop wire saw wire rope should not be less than... It should be less than 60% of the minimum breaking tensile strength of the wire rope. The connection strength of the wire saw joint should be tested under the following conditions.

---New product design specifications;

---Changes occur in key raw materials (joints, wire ropes) during production;

8.5 Bond strength between abrasive layer and steel substrate

8.5.1 Test Apparatus The support base is made of cemented carbide or tool steel with a hardness of not less than 60 HRC. The inner diameter of the support base is determined by the outer diameter of the bead base. The outer diameter of the material should be 0.10mm to 0.15mm larger than that of the beaded matrix. The measuring range of the material testing machine should not exceed 30kN, and the accuracy should be grade 0.5.

8.5.2 Test Method The testing method steps are as follows:

a) Randomly cut 10 beads from the wire saw sample, retaining the steel wire rope and fixing material inside the inner hole, and place the bead base under test on the top and bottom. The end face is ground flat.

b) The length of the abrasive layer and the outer diameter of the substrate of the beads were measured using a vernier caliper with a graduation of

0.02 mm, and the values were accurate to the decimal point. One. Place the specimen on the support, then start the testing machine at

0.5 mm/min at the center axis position of the steel substrate. The load is applied uniformly at a displacement velocity (as shown in Figure 5) until the abrasive layer peels off from the substrate, and the shear force (F1) at the time of peeling is recorded. The shear stress (tau1) value is calculated according to formula (1).

8.6 Fixing strength of beads and wire rope

8.6.1 Test Apparatus The fixture is made of cemented carbide or tool steel with a hardness of not less than 60 HRC. There should be a bisected circular hole at the center of the lower fixture. The hole diameter is determined based on the wire rope diameter. For samples with a bead outer diameter greater than

5.3 mm, the hole diameter should be

1.0 mm larger than the wire rope diameter. 1.5mm; for samples with an outer diameter of no more than 5.3mm for the beads, the diameter of the circular hole should be 0.2mm~0.5mm larger than the diameter of the wire rope. Material Testing The measuring range should not exceed 30kN, and the accuracy should be

0.5 grade.

8.6.2 Test Method The testing method steps are as follows:

a) Remove all the fixing material from the surface of the steel wire rope at both ends of the beads.

b) The surface of the wire rope in the clamping part needs to be sandblasted.

c) Fix one end of the sample wire rope to the upper clamp of the material testing machine, and fix the test beads at the other end of the sample to the testing machine. The beads are placed on the lower clamp (as shown in Figure 6). They are moved at a constant displacement speed of 25 mm/min, and the shear force during bead peeling is recorded. (F2).

d) After the beads are completely separated from the wire rope, remove any remaining fixing material from the inner hole of the base material. Use an indexing value of 0.02mm. A vernier caliper is used to measure the inner diameter and length of the bead matrix, accurate to one decimal place. Shear stress (tau2) values are calculated according to... Calculate using equation (2).

8.7 Fixing strength between the pressure ring and the wire rope Clamp the wire saw specimen on the material testing machine, as shown in Figure

7.The test conditions are the same as in 8.6.1.Apply force to move the pressure ring by at least [a certain amount of force]. Record the maximum force (F3) at a displacement of 25mm. Calculate the ratio of F3 to the minimum breaking strength of the corresponding specification wire rope. Five pressure rings were tested sequentially, and each pressure ring should meet the requirements of 7.8.

8.8 Connection strength of wire saw joints The test conditions are the same as in 8.6.1.For conventional wire saws, the wire saw specimen is clamped on a material testing machine as shown in Figure 8, and force is applied until the wire... The rope is released from the joint, and the maximum force (F4) at the time of release is recorded; for closed-loop wire saws, the sample containing the wire rope braided joint is clamped in the material test chamber. During the machine test, ensure the braided section is centered in the clamp, as shown in Figure

9.Apply force until the wire rope breaks, and record the maximum force at the point of breakage. (F4). Calculate the ratio of F4 to the minimum breaking strength of the corresponding specification wire rope.

8.9 Maximum operating speed The maximum operating speed is not tested, but it should be specified in the product instruction manual.

9.2 Factory Inspection

9.2.1 Sampling and Inspection Products manufactured in the same shift, using the same process, and with the same formula are counted as one batch. The appearance and length of the wire saws are fully inspected. Twenty beads are randomly selected from each batch of wire saws to check the outer diameter of the beads and the length of the abrasive layer. For other items, an additional sample with a length of 1.0m should be produced during the production of the same batch of products as a test specimen, according to the following requirements. Conduct the inspection.

a) Select 10 beads to test the bonding strength between the abrasive layer and the steel substrate;

b) Select another 10 beads to test the fixing strength between the beads and the wire rope; for the spring wire saw, select 5 pressure rings to test the pressure rings. The fixing strength with the wire rope.

9.2.2 Determination If all inspection items pass, the batch of products is considered qualified; if one or more inspection items fail, the batch of products is considered unqualified.

9.3 Supervisory Inspection

9.3.1 Sampling and Inspection One wire saw was randomly selected from the same batch of products as a sample. Inspect the length and appearance of the wire saw. Randomly select 20 beads and check their outer diameter and abrasive layer length. For other items, inspection shall be carried out according to the following requirements.

a) Select 10 beads to test the bonding strength between the abrasive layer and the steel substrate;

b) Select another 10 beads to test the fixing strength between the beads and the wire rope; for the spring wire saw, select 5 pressure rings to test the connection between the pressure rings and the wire rope. The fixing strength of the wire rope.

9.3.2 Determination If all inspection items pass, the batch of products is considered (qualified); if one or more inspection items fail, the entire batch of products should be inspected. Take double the number of samples and retest the non-conforming items. If the retest still fails to meet the requirements, the batch of products is considered non-conforming.

10.1 Mark

10.1.1 Product Marking Product markings, affixed to the product in the form of labels, should include, but are not limited to, the following.

a) Manufacturer's name and trademark;

b) Product Name;

c) Product marking;

d) Cutting direction;

e) Product number;

f) Production date.

10.1.2 Outer Packaging Markings The following information should be noted on the packaging box.

a) Manufacturer's name and trademark;

b) Product Name;

c) Product marking;

d) Product number;

e) Production date.

10.2 Packaging

10.2.1 Wire saws should be bundled into a ring according to the size of the packaging box and placed inside the packaging box.

10.2.2 The gaps inside the packaging box should be filled with soft material, and a quality certificate and product instruction manual should be attached.

10.2.3 The packaging should be sturdy and aesthetically pleasing.

10.3 Transportation During transportation and loading/unloading, the items should not be thrown, subjected to heavy pressure, exposed to direct sunlight, or directly exposed to rain or snow.

10.4 Storage Wire saws should be stored in a dry, well-ventilated warehouse with a room temperature of 5°C~35°C and a relative humidity of less than 80%. After entering the warehouse, they should be stored separately according to their type. Storage period. The storage period is 2 years. Wire saws that have exceeded the storage period should be re-inspected according to the provisions of this document, and can only be used after passing the inspection.