Straight cutting vs Rotary cutting vs Tilting cutting

In machining processes, we categorize cutting methods based on the movement of workpiece:

1. Straight cutting: ?

Straight cutting is the basic processing method of all diamond wire cutting machines. In straight cutting, the diamond wire and the workpiece remain stationary, and the workpiece is pushed forward by the worktable slide to achieve the purpose of cutting.

During the cutting process, the contact length between the saw wire and the workpiece is constantly changing. The constant change in contact length leads to uneven surface processing of the workpiece. When cutting large-sized workpiece, the chips are not easy to be removed from the saw seam, and the cooling effect of the coolant is reduced.

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2. Tilting cutting: ?

The tilting cutting is mainly the workpiece swing. The diamond wire remains stationary while the workpiece swings. The tilting cutting ensures a constant arc contact between the wire saw and the workpiece during the cutting process, thereby ensuring that the contat length remains unchanged during the entire sawing process.

Compared with straight cutting, tilting cutting can reduce the sawing force by 35%, the surface roughness of the slice is reduce from 2.2μm to 0.5μm (Reference sic slicing), and the surface damage layer is also greatly improved.

However, the structure of the tilting cutting system is relatively complex. When the wire saw is cutting at high speed and swinging at high frequency, the vibration will affect the processing accurancy of the workpiece.

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3. Rotation cutting: ?

The diamond wire does not move, the workpiece rotates continuously, and the workpiece and the diamond wire onlly have one point of contact, which reduces both the sawing force and the heat generated by sawing, which is beneficial to extending the life of the wire saw and improving the surface quality of the finished workpiece.

However, as the cutting process proceeds, the turning radius of the workpiece gradually decreases, and the cutting speed synthesized by the movement speed of the wire saw and the feeding speed of the ingot rotation also gradually decreases, and the surface quality of the cut workpiece near the rotation axis is reduced.

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The relationship between the three processing technologies of Straight cutting, tilting cutting, and rotation cutting is as follows: straight cutting has the largest contact area between the diamond wire and the workpiece, followed by tilting cutting, and the rotation cutting has the smallest contact area.?

Everyone knows that A chopstick is easy to be broken, while a bunch of chopsticks are not. The smaller the contact area, the easier it is to cut. Rotary cutting is like a chopstick, while straight cutting is like a bunch of chopsticks. Smaller contact area, better chip remove and less heat rasing, thus make the rotary cutting higher cutting efficiency.?

Each of the three cutting processing has its own advantages. Straight cutting is currently the most widely used cutting method. Especially for fragile materials. Because the workbench is fixed, the cutting accurancy is the higest.?

During the Tilting cutting process, the diamond wire swings, and the gap cut in the previous swinging process, the contact between the diamond wire and the workpiece is shortened, making it easier to cut. This is suitable for cutting materials with large size or heavy weight, and for workpieces that do not require particularly high cutting quality.?

As for the rotation cutting, the workpiece rotates, but the diamond wire does not swing. During cutting, the contact area between the diamond wire and the workpiece is very small, so it is easy to cut. The workpiece rotates at high speed while the diamond wire continuously grinds the previously cut slit. The number of grinding times is more than the number of tilting cutting times, so this cutting process has the best effect. This cutting method is suitable for small-sized or light-weight materials, but not for oversized and overweight workpieces.?

In summary, the cutting effeciency relationship of the three types of slices of diamond wire cutting machine is: ?rotation cutting > tilting cutting > straight cutting. But each has its own advantages. Rotation cutting has advantages for small size and light weight materials, and tilting cutting has advantages for large size and overweight materials. While straight cutting has advantages for fragile material, and high cutting accurancy. It is worth noting that rotation cutting requires higher rigidity and stability of the machine bed and rotaty table.

Ensoll's new horizontal cutting machine, ESH600-4T, features three cutting functions: straight cutting, tilting cutting, and rotary cutting. Choose the one you prefer!