Cutting ultra-hard and brittle material is not an easy task. Traditional cutting machines often struggle to maintain accuracy while avoiding cracks or physical damage. This is the place where a rotary diamond wire saw, which comes in the picture. Known for its ability to make accurate, smooth and efficient cuts, this machine is a game-changer for industries that work with challenging materials.

Rotary Diamond Wire Saw Working Principle

The function of a diamond wire cutting machine is simple but highly effective. The machine uses a thin wire coated with industrial diamonds. This wire moves continuously in a closed loop system while moving at high speed. When the wire comes in contact with the workpiece, the small diamond particles remove the layer of the material by layer.

Unlike traditional saws relying on teeth or blades, this process is more like an accurate piece. Because the cutting force is evenly distributed with the wire, the risk of cracking or breaking the workpiece is very low. The constant speed of the wire also ensures smooth and similar cuttings.

In many models, water or coolant flows on the cutting area to reduce heat and wash debris. This not only improves cutting speed but also enhances the life of the wire. The result is a clean, accurate cut with minimum material waste, which is important when working with expensive materials such as silicon wafers or sapphire glass.

Advanced Rotary Diamond Wire Saw – SH60-R

The SH60-R rotary Diamond wire saw, designed for industries that require smooth and accurate cutting of hard, brittle materials. 

This high-capacity machine is perfect for cutting sapphire, quartz, ferrites, ceramic and composite oxide. Its strong frame and powerful drive allow it to handle heavy workpieces of up to 500 kg without losing it.

SH60-R uses a rotary cutting tool for stone and ceramics that continues to rotate for a stable and chip-free bite. It keeps running the wire smoothly without vibration, which is very important for delicate materials. The rotary cutting changes the workpiece during cutting mode, resulting you a smooth and even surface.

One of the biggest benefits of this machine is its low kerf loss. The wire makes an ultra-split cut, which is as narrow as 0.4 mm, which saves the material and reduces edge damage. The abrasive cutting action uses very little force, so it prevents chipping and microcracks.

The SH60-R also comes with cooling and mist collection to clean and make the process. Its independent PLC control system simplifies the operation, which requires no external computer. This machine is perfect for high-volume production where accuracy, stability and smooth slicing are the most important.

Major features that ensure accurate cutting

One of the main causes of the Rotary Diamond Wire Saw is its ability to give accurate cuts. These machines come up with many characteristics that help to achieve high accuracy.

• They have a stable frame and a worktable that reduces vibration during cutting. Even slight vibrations can cause irregular cuts, so stability is very important. Second, wire stress is controlled automatically. Proper stress keeps the wire straight and prevents bending, which can cause an uneven piece.
• Modern rotary diamond wire saws are also equipped with closed-loop wire drive systems. This means that the wire moves at a constant speed, even when cutting hard material. Some machines have digital controls that allow operators to set cutting parameters with high precision.
• Another major feature is the ability to handle large workpieces without losing accuracy. Many machines have a huge scope and high load capacity. This allows industries to cut several wafers or blocks at a time, which improves productivity.

Benefits of Using a Rotary Diamond Wire Saw

The benefits of a durable diamond wire saw technology go beyond accurate cutting. One of the biggest benefits is reduced Carf Loss. Carf is the material lost during loss cutting. Since the diamond wire is very thin, less material is wasted, which saves money.

Another benefit is the smooth surface finish. The cutting process passes behind a flat and bright surface, which reduces the need for additional polishing. This saves both time and cost.

The Rotary Diamond Wire saw also provides high efficiency. They can cut several pieces at the same time, and the process is faster than traditional saw methods. Machines are also more energy-efficient because they use a piece of action instead of cruel force.

In addition, these saws are versatile. They can handle a wide range of materials, from semiconductors to ceramics to optical glass. This flexibility makes them a valuable investment for many industries.

The use of water cooling of watercooling and accurate control systems makes them safe and environmentally friendly. There is less dust and noise during the operation, which creates a better working environment for operators.

Application in various industries

Rotary diamond wire saws are used in many industries where accuracy is important. In the semiconductor industry, they are used to slice silicon cylinders into thin wafers for chips and solar cells. Because the cuts are smooth and accurate, wafers require less post-processing, which saves time in production.

In the optoelectronic industry, they are used to cut sapphire substrates for LED, camera lenses and smartphone screens. These ingredients are very difficult, but the diamond wire noticed that the microcrack makes a clean cut without producing it.

The advanced ceramic industry also benefits from this technique. Ceramics are brittle and can easily break under stress. The gentle grinding action of the diamond wire helps in avoiding damage.

In magnet construction, rotary diamond wire saws are used to cut magnetic materials into accurate shapes. Smooth cuts ensure that magnets maintain their properties.

Even in research laboratories, these machines are used to prepare samples for testing. Scientists often require very thin, innocent slices of materials to analyse their properties, and a rotary diamond wire saw, which is perfect for the task.

The material used for diamond wire saw manufacturing.

The quality of a rotary diamond wire saw depends largely on the materials used to make it. Frames and worksteables are usually made from high-power steel or aluminium alloys to provide stability and durability. These precision wire saw for hard materials also oppose vibration and deformation under heavy loads.

Wire is the heart of the machine. It is made from high-teeth steel core wire that is coated with synthetic diamond particles. These diamonds are firmly bound to wire using electroplating or resin bonding techniques. The quality of the diamond coating determines the sharpness and lifetime of the wire.

Choosing the right rotary diamond wire

Choosing the right rotary diamond wire depends on your specific requirements. 

• Consider the size of the workpiece you need to cut. If you are cutting large silicone ingots or several blocks at once, you will need a huge worktable and a high-load model.
• Look at the exact requirements. For semiconductor applications, even a small error can ruin the final product. Choose a machine with automatic stress control and closed-loop speed regulation to ensure accuracy.
• You should also check the wire speed range and cutting capacity. Some materials require high speed, while others require slow, more controlled cuttings. A machine with adjustable settings will give you more flexibility.
• Another factor to consider is ease of use. Look for machines with user-friendly control, clear performance and easy maintenance access. It reduces downtime and training costs.

Manufacturer of Cutting Tools for Semiconductor Materials

When it comes to cutting equipment for semiconductor and other hard materials, Vimfun is a reliable name. They specialise in the design and manufacture of advanced wafer slicing equipment that meets the strict requirements of industries such as semiconductors, optoelectronics and advanced ceramics.

Their machines are known for their high precision, durability and efficiency. Rotary diamond wire saws of Vimfun include advanced control systems, stable structures and excellent wire stress management. This allows them to make consistent, smooth and accurate cuts.

They continue to improve their products based on industry needs, provide solutions that save time, reduce physical waste and improve the quality of production. For any company working with hard and brittle materials, Vimfun’s equipment is a reliable option.