Cutting with diamond wire ...                          

A comparison of laboratory - saws that work with varying diamond wires:

Open end wire – saws

For a long time known they are the epitome of precision cuts for the sample preparation in microscopy.  Extremely fine wires can be used (eg 100 microns in diameter) which makes it possible to cut very thin slices (the effective slice thickness depends on the material properties and can not be quantified). This saws work with low wire speed (eg, 2m/s), the contact pressure between wire and sample (gravity feed) is in the gram range (eg, 100g). No appreciable heat is created and in addition, the cutting wire is continuously wound on a metal cylinder, to whom he gives the residual heat. The cutting times are relatively long, which is, since the saw is designed for small samples, irrelevant. As the diamond wire constantly changes the cutting direction (the wire is  typically 10m in length) a self-cleaning effect is created on the wire, but will also produce fine scratches (less than 5μm depth). The fluid is used solely for the removal of particles to keep the wire clean.

Endless wire saws

Still little known, since the introduction into the market   just began, this saw type has   unimagined applications. The wire speed is very high (typically 20 m/s), the cutting times correspondingly short. Hard materials such as glass and ceramics can be easily cut, the heat generated during cutting can be partially eliminated by a liquid (usually water). The wires range from 0.35 to 0.60 mm. Soft materials have a risk of sticking  to the wire (by reducing the wire speed this can sometimes be prevented).  If necessary, these saws can cut parts led by hand (shapes). It is of particular interest that in case of accidental touching the ongoing wire, no cuts on fingers are produced. This advantage is unique and not known from others saw types. The wire exchange can be accomplished very easily and quickly. Since the diamond wire runs in only one direction, the surface is largely groove – free.  Normally this saw type is used in relation with electrical feed.
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The QUALITY vs. QUANTITY Issue

Qualityⁿ

Well Diamond Wire Saws, Inc. believes quality is quantifiable and our saws are designed, manufactured and perform to help others achieve the quality results they seek. Regardless of the cutting task and whether the application is for research and development, production, quality control or failure analysis, Well Diamond Wire Saws, Inc. offers precision cutting instruments that satisfy the most demanding cutting needs. We invite you to explore our diamond wire cutting technology further.

The "Well" Design: Well Diamond Wire Saws are designed to perform smooth cuts on virtually any material regardless of its hardness, softness, brittleness, or pliability. The gentle cutting action of the reciprocating diamond embedded wire ensures that the walls of the cut material are both straight and smooth having negligible surface roughness. For applications where the quality of the cut surface finish is of significant importance, we believe there is no other cutting process that offers this quantifiable result.

Cutting Methodology – Wire Embedded with Diamonds

We use the highest quality stainless steel wire of various diameters ranging from 0.055 to 0.60 millimeters. Then, through a proprietary process, we embed diamonds of various grits sizes ranging from 10 to 64m into the wire. The wire of between 10 and 40 meters length, depending on the instrument, is then wound onto a precision-machined drum. The motor that drives the drum saw reciprocates in its direction. For this reason the part being cut must be mechanically clamped or "fixtured" onto the stage or sample holder. Tensioning of the wire is achieved by wrapping the loop of the diamond wire around a weighted pulley. As the finite length, tensioned wire is wound onto the drum in both a forward and reversed direction the diamonds gently remove material from the surface in a straight, precise manner. The result is an extraordinarily smooth surface with sharp corners.

Feeding the wire into through the sample

Since the minimum of force is applied to the sample, either via gravity feed or via weights, the "Well" cutting procedure insures consistent forces throughout the entire cut. It is acknowledged that cutting times are somewhat longer than conventional cutting methods. It must be determined whether the goal is to achieve a fast, often violent cut or, as with the Well process whether a slower, gentler, and smooth cut will produce the desired outcome. The slower cuts achieved with the Well Diamond Wire Saws produce no measurable heat build-up commonly associated with other cutting processes, therefore no coolant or cutting fluids are required. Also, since virtually no "burning" of the sample occurs during the cutting process both the odors and noise often accompanying other methods is eliminated making the Well process environmentally acceptable under the most stringent regulations.

Safety First

The diamond wire cutting tool travels at a relatively slow rate of speed, which is continuously adjustable up to 2.5 meters per second. This low rate of speed helps ensures a gentle cutting action as well as makes the "blade" safe to the touch while the cut is in process. In fact, the operator can watch the cut in process from as closely as he or she desires since no protective hood is required. Due to the low cutting forces employed the sample requires a bare minimum of fixturing pressure. And, in the rare event of a wire breakage during the cutting process, the machine immediately shuts off automatically. Also, end-stop switches can be engaged to stop the saw either when the cut is finished or when grooves of a defined depth are needed.

Quality²

In order to produce cutting instruments capable of delivering precision, repeatable cuts Well Diamond Wire Saws, Inc. utilizes the very best components available in every model saw it manufactures. Ever since the company manufactured and delivered its first saw, the design and manufacturing emphasis has always been to produce instruments that will operate 24 hours a day, 365 days per year. Recently we learned that the first saw ever delivered by the company is still in operation today. Regardless of whether the instrument is made in our Mannheim, Germany or Le Locle, Switzerland manufacturing facility, our personnel guarantee every instrument meets and exceeds the highest quality standards.

United States:

Telephone:  770-582-9357        Fax:   770-582-9339       

E-mail: wellsaws.dw@welldws.com

Address:  Well Diamond Wire Saws, Inc.

4708 S. Old Peachtree Road, 500 D

Norcross GA  30071 USA