Experimental Investigation on Diamond Band Saw Processing of Resin Mineral Composites

At a Glance

Metadata	Details
Publication Date	2024-04-15
Journal	Materials
Authors	Jiahao Sun, Jianhua Zhang, Weizhou Gu, Yunfang Long, Chuanxin Guo
Institutions	Shandong University
Citations	1
Analysis	Full AI Review Included

Executive Summary

This research validates the feasibility and characterizes the process mechanics of precision diamond band saw processing for Resin Mineral Composites (RMC), a material critical for high-end CNC machine tools due to its superior damping and corrosion resistance.

Processing Feasibility: Diamond band sawing is confirmed as an efficient method for RMC, achieving a low average surface roughness (Ra) between 1.8 and 2.6 µm.
Force Characteristics: Stable sawing forces are low and controllable: Feed force (F_f) is 3.5-5.5 N, and Tangential force (F_t) is 1.0-2.0 N. Forces are inversely proportional to sawing speed (V_s) and directly proportional to feed speed (V_f).
Optimal Parameters: The best surface quality (lowest Ra) is achieved at the highest tested sawing speed (1600 m/min) and the lowest feed speed (4 mm/min).
Process Stability: Maintaining a constant ratio of sawing speed to feed speed (V_s/V_f) ensures consistent surface roughness and morphology, allowing for increased production capacity without sacrificing quality.
Lateral Force Fluctuation: Significant lateral force instability is observed in mineral-rich areas, with fluctuations up to 94.86% higher than in other regions, linked to uneven stress when diamond particles cross the resin-mineral interface.
Critical Processing Defect: A consistent step structure (ladder-like defect) with a height of 10-15 µm is generated at the resin-mineral interface, potentially compromising RMC component performance and necessitating subsequent precision finishing.

Technical Specifications

Parameter	Value	Unit	Context
RMC Base Material	Bisphenol A Epoxy Resin (618A)	N/A	Binder material
Aggregate Types	Jinan Blue Granite, Quartz Stone	N/A	Filler materials
Saw Blade Dimensions	4800 x 50 x 0.65	mm³	Diamond band saw specification
Diamond Mesh Number	80	N/A	Continuous teeth type
Sawing Speed (V_s) Range	1120 to 1600	m/min	Experimental range
Feed Speed (V_f) Range	4 to 8	mm/min	Experimental range
Stable Tangential Force (F_t)	1.0 to 2.0	N	Low force level during stable sawing
Stable Feed Force (F_f)	3.5 to 5.5	N	Higher force level during stable sawing
Minimum Surface Roughness (Ra)	1.979 (Resin), 1.877 (Mineral)	µm	Achieved at V_s=1600 m/min, V_f=4 mm/min
Lateral Force Fluctuation Increase	94.86	%	Maximum increase observed in mineral-rich areas
Resin-Mineral Interface Step Height	10 to 15	µm	Height of the ladder-like processing defect
Granite Compressive Strength	202.43	MPa	Aggregate mechanical property
Quartz Compressive Strength	141.52	MPa	Aggregate mechanical property

Key Methodologies

RMC Material Preparation: RMC workpieces were prepared by mixing Bisphenol A epoxy resin (618A) with 20% mass fraction of 593 curing agent, diluent, and fly ash. Graded Jinan blue granite and quartz stone were used as aggregates.
Interface Bonding Treatment: Aggregate surfaces were treated with a silane coupling agent solution (1:1:8 volume ratio of coupling agent:deionized water:absolute ethanol) at 20 °C for 10 minutes to improve interface bonding strength.
Casting and Defoaming: The mixed materials were cast into molds, followed by a pressure plate casting process (1 kg pressing plate) combined with 1.5% mass fraction dimethyl silicone oil defoaming agent to minimize porosity.
Sawing Setup: Experiments were performed on a W-900 band saw machine using a 4800 x 50 x 0.65 mm³ diamond band saw blade (80 mesh, continuous teeth).
Force and Vibration Measurement: Sawing forces (F_t, F_f, F_l) were measured using a Kistler 9257B dynamometer. A Kistler 8763B050BB three-axis acceleration sensor monitored fixture vibration.
Signal Processing: Raw force signals were filtered using a Fast Fourier Transform low-pass filter (5 Hz cutoff frequency) and smoothed using the neighbor averaging method (500 window points) to extract stable force values.
Surface Topography Analysis: Machined slices were analyzed using a Sensofar S neox 3D Optical Profiler in laser confocal mode (10x lens, 0.3 NA). Surface roughness (Ra) was calculated according to the ISO 21920 standard.
Defect Characterization: The height of the step structure at the resin-mineral interface was determined by averaging the height levels of cross-sections taken perpendicular to the interface boundary.

Commercial Applications

High-End CNC Machine Tools: RMC is essential for manufacturing precision machine tool components (e.g., beds, guide rails) due to its high damping capacity (reducing vibration by several times compared to gray cast iron) and high stiffness.
Precision Component Manufacturing: The diamond band sawing technique offers an efficient, high-precision method for rough-cutting RMC components that require smooth surfaces and high dimensional accuracy, such as long guide rails.
Aerospace and Defense: Application in components requiring high strength, low density, and excellent corrosion resistance, where RMC’s ability to integrate complex shapes is beneficial.
Medical and Electronics Equipment: Use in sensitive instruments where stability under high-speed operation and resistance to environmental corrosion are necessary.
Material Processing Optimization: The finding that maintaining a constant V_s/V_f ratio ensures consistent quality allows manufacturers to optimize production speed (V_f) by simultaneously increasing sawing speed (V_s), improving throughput without sacrificing surface finish.

View Original Abstract

Resin mineral composite (RMC) is a new material with several times the damping properties of gray cast iron and great corrosion resistance. Due to its overall brittleness, sawing with a diamond band saw would be a suitable method. In this research, sawing experiments are carried out to study the sawing force characteristics of the material and its surface morphology during the processing. The results show that the feed force level is in the range of 3.5~5.5 N and the tangential force level is relatively low. The distribution of resin mineral components does not have a significant impact on the average sawing force but increases the fluctuation of the lateral force signal. The maximum fluctuation volume is 94.86% higher than other areas. Uneven lateral force, generated when diamond particles pass through the resin-mineral interface, is one of the causes of fluctuations. The machined surface of RMC has uniform strip scratches and a small number of pits. Maintaining a constant ratio of sawing speed to feed speed can result in approximately the same machined surface. A step structure with a height of about 10 μm appears at the interface of resin minerals. As a processing defect, it may affect the performance of RMC components in some aspects, which need a further precision machining processing.

Tech Support

Original Source

DOI: https://doi.org/10.3390/ma17081814

References

2021 - Digital Twin Control of Multi-Axis Wood CNC Machining Center Based on LinuxCNC [Crossref]
2018 - Improving machining accuracy of cnc machines with innovative design methods [Crossref]
2016 - Research on Mixed Fiber Reinforced Resin Mineral Composites
2017 - Shear bond strengths of composite resin and giomer to mineral trioxide aggregate at different time intervals
2017 - Study on Dynamic Characteristics of Resin mineral Composite Grinding Machine Bed
2019 - Mechanical Properties of Mo Fiber-reinforced Resin Mineral Composites with Different Mass Ratio of Resin and Hardener [Crossref]
2022 - Comparison on forming quality and static strength for self-piercing riveting joints of laminated plates with different sandwich materials and AA5052 aluminum alloy
2021 - Influence mechanism of multi-factor on the diameter of the stepped hole in the drilling of CFRP/Ti stacks [Crossref]