Mechanical model of diamond wire sawing for curved surfaces

Abstract

Diamond wire sawing is effective in machining complex parts. During the wire-cutting process, the cutting force affects the wire causing different shape changes, thereby affecting the machining quality. This paper introduces a wire sawing mechanical model for curved surfaces that considers the interdependence between the spatial motion of the wire, cutting force, and material removal. A wire bow angle measurement system was built using spring displacement sensors, and the accuracy of the mechanical model was verified through curved surface cutting experiments. The mechanical model was used to analyze the influences of the machining parameters and twist surface cutting process on the wire bow angle. The results showed that the sawing twisted surface increased the float amplitude of the wire bow angle. The wire feed rate at both ends varied with time owing to the wire twisting motion. The change in the wire feed rate at both ends was the primary factor affecting the change in the wire bow angle during the twist surface-sawing process. When sawing twisted, curved surfaces, the wire bow angle gradually decreases with increasing preloading force and wire velocity and a decreasing workpiece feed rate. Increasing the wire velocity and decreasing the workpiece feed rate can reduce the float amplitude of the wire bow angle, thereby enhancing the stability of the cutting process. This study lays the theoretical groundwork for understanding wire deformation during curved surface sawing.