Experimental study of the cutting performance of free-abrasive wire sawing in a magnetic field

In view of the low cutting efficiency and large kerf loss of traditional free-abrasive wire sawing, a method of free-abrasive wire sawing in a magnetic field is proposed. Magnetic abrasive grains are adsorbed onto the surface of a magnetised wire by the magnetic force. Therefore, more magnetic abrasive grains are carried into the cutting area during the cutting process. This mechanism is helpful for improving the cutting performances of wire saws. The adsorption mechanism of a magnetically induced free-abrasive grain is described briefly. A series of observation experiments are performed. The results show that the magnetised wire can adsorb magnetic abrasive grains and that the quantity of magnetic abrasive grains in paramagnetic regions of the magnetised wire surface increases with increased magnetic field intensity, thereby verifying the presumed adsorption mechanism. Cutting experiments are performed, and the results show that changes in magnetic field intensity, feed rate of the workpiece, running speed of the wire, viscosity of the cutting fluid and mass fraction of the magnetic abrasive grains have a significant impact upon the cutting performance of free-abrasive wire sawing in a magnetic field.