다이아몬드 와이어
What Is Diamond Wire?
Diamond wire is a high-tensile metal wire coated with a layer of nickel that embeds fine diamond abrasive particles.
It is the core cutting medium used in all diamond wire saws — converting mechanical motion into a precision abrasive slicing process.
The base wire, often made of high-carbon steel or tungsten steel, is electroplated with a uniform nickel bonding layer (≈ 20–25 μm) that holds synthetic diamond grains.
This structure provides both 유연성 그리고 cutting aggressiveness, enabling stable, high-speed cutting of hard, brittle, and high-value materials.
Manufacturing Process of Diamond Wire
The performance of a diamond wire depends on the precision of its manufacturing process.
Each step ensures particle adhesion, wire uniformity, and controlled surface roughness.
| Stage | 설명 |
|---|---|
| 1. Core Wire Preparation | High-strength metal wire (usually Ø 0.3–0.8 mm) is drawn to the target diameter and cleaned ultrasonically. |
| 2. Nickel Electroplating | A thin nickel layer (20–25 μm) is electroplated to bond the diamond grains uniformly. |
| 3. Diamond Grit Embedding | Diamond particles (D213–D75) are dispersed and embedded on the wire surface through electrostatic or mechanical deposition. |
| 4. Thermal Treatment | Heat stabilization relieves internal stress and enhances grit adhesion. |
| 5. Inspection and Polishing | Surface uniformity is tested under a microscope; defective sections are removed before packing. |
The result is a flexible, high-tensile wire that maintains consistent abrasive distribution even under high-speed motion.
Types of Diamond Wire
Diamond wire used in precision cutting is available in two major structural forms, each designed for different machine systems and cutting applications:
Spool (long-length) diamond wire — typically used in traditional reciprocating or multi-wire saws.
Endless (loop-type) diamond wire — used in modern continuous cutting systems.
Both types employ the same abrasive concept: a high-strength metal wire electroplated with diamond particles. However, their geometry and motion pattern determine cutting performance, machine compatibility, and operational efficiency.
Loop Wire Performance Specifications
| 매개변수 | Typical Range | 설명 |
|---|---|---|
| 와이어 직경 | 0.3 – 0.8 mm | Depends on application and material hardness. |
| Tensile Strength | ≥ 150 N | Prevents elongation or breakage under 80 m/s wire speed. |
| 표면 거칠기(Ra) | ± 1.25 μm | Ensures uniform abrasion and minimal surface marking. |
| Coating Thickness | 20 – 25 μm | Stable grit retention layer. |
| Diamond Grain Size | D213 – D75 | Smaller grit = smoother surface, larger grit = faster cutting. |
| Cutting Lifespan | 50 – 200 m² | Depending on material and coolant system. |
Applications of Diamond Wire
Diamond wire is widely used across precision industries that require low-damage, non-thermal material removal:
Semiconductor: Slicing silicon ingots into wafers.
Optics: Cutting sapphire, coated glass, and lens substrates.
Ceramics: Sectioning alumina and zirconia blocks.
Magnetics: Precision cutting of NdFeB and ferrite magnets.
Carbon & Graphite: Forming EDM electrodes and crucibles.
Composites: Slicing CFRP and polymer-on-glass diffusers.
그만큼 cold-cutting nature of diamond wire prevents microcracks and stress distortion — crucial for optical or layered materials.
Endless Diamond Wire Models and Specifications
Videos of Different Electroplated Diamond Wire
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Abrasive Wire Quality Inspection and Testing
Every production batch undergoes strict laboratory verification to ensure uniformity and durability.
| Test | Method | 목적 |
|---|---|---|
| SEM Microscopy | Scanning Electron Microscope | Verifies diamond distribution and coating integrity. |
| Tensile Strength Test | Load cell measurement | Confirms wire resistance to elongation and rupture. |
| Coating Thickness Measurement | Metallographic analysis | Ensures consistent electroplating layer. |
| Fatigue Life Test | Repetitive bending test | Simulates high-speed operation wear. |
All Vimfun diamond wires meet ISO 9001 production and internal endurance testing standards.
FAQs —Diamond Wires
Q1. What is diamond wire made of?
A high-strength steel or tungsten core, coated with a nickel bonding layer embedded with synthetic diamond grit.
Q2. Can diamond wire be reused?
No. Once the diamond coating wears off or the wire is stretched, performance declines sharply. Always replace after visible wear or decreased cutting rate.
Q3. What determines diamond wire lifespan?
Material hardness, grit size, coolant flow, and cutting parameters. Proper cooling can double wire life.
Q4. How is the diamond grit attached?
Through electroplating — nickel ions deposit around diamond particles, fixing them firmly onto the wire.
Q5. Which wire diameter should I select?
Use thinner wires (0.3–0.35 mm) for fine optical materials and thicker wires (0.65–0.8 mm) for dense ceramics or carbon composites.