阻尼降噪机理及消音金刚石锯片的研究
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摘要
金刚石锯片广泛地应用于切割石材、混凝土、玻璃、水晶、石墨电极等硬脆材料。但是金刚石锯片的切割啸叫声带来了极大的噪声，通常切割噪声达105dB以上。噪声污染严重地危害人们的身体健康。
首先合理地设计了金刚石锯片的基体结构。试验出合理的基体连接工艺，并成功地制备出具有消音功能的金刚石锯片的基体。采用双面点焊的方式，熔焊面积为25％左右。该结构设计的消音机理为：层与层之间存在一层非常薄的空气层，形成不同金属与空气的多层结构，即A金属-空气-B金属-空气-A金属或A金属-空气-B金属-空气-B金属-空气-A金属等多层结构。当金刚石工具在切割激励的条件下，基体之间的空气层在振动的作用下来回地流动，由于夹层中间的空气流动，吸收了一部分振动能量，从而导致较低的噪声辐射。由于不同物质的固有振动频率不同，振动在不同物质间传播时，振动会降低，由振动产生的噪声也会降低。此外，由于夹层B为高塑性金属，振动使其内部的位错产生滑移和攀移，以消耗部分振动能，也是降低噪声的原因之一。
采用敲击噪声测试，确定了在锯片的外三分之一处振动最为强烈，同时消音锯片的噪声衰减仅为1.0秒左右，比普通金刚石锯片(15秒左右)快得多。
另外，本文还研究了夹层厚度对降噪效果的影响，通过试验确定了最合理的夹层厚度为0.10毫米。通过现场切割噪音测试，在干切的条件下，该消音结构的金刚石锯片切割噪声为86.69dB，而普通金刚石锯片的噪声为104.5dB，比普通锯片的噪声降低了17.81dB。达到了我国《工业企业卫生标准》中规定的90dB的要求。
Diamond saw blade is a tool which is widely used in cutting hard brittle materials, such as stone, concrete, glass, crystal, graphite electrode and so on. At the same time, the cutting noise usually outstrips 105dB while cutting. The noise pollution badly jeopardizes the health of the operating workers.
Matrix structure of diamond saw blade was designed rationally. Through experiment, rational joint technology was defined and matrix of diamond saw blade with noise damping was prepared. Matrix was jointed by two-sided spot welding, and welding area is 25% or so of matrix. Mechanics on noise reduction of the structure is as followed: There is a very thin air layers between the matrix, so the structure of multi-layer is formed. That is metal A-air-metal B-air-metal A or metal A-air-metal B-air-metal B-air-metal A. On the cutting motivation conditions, air layer between two metal layers is flowed to-and-fro, which can absorb a part of motivation energy, so it leads to low noise radiation. In addition, Because of different matter with different natural frequency, vibration of saw blade will weaken, when it transmits in the different matter. So the noise will be reduced. At last, vibration can make dislocation of metal slip and climb, which dissipate the vibration energy to reduce noise while cutting.
Through noise testing, we draw a conclusion that vibration of outer 1/3 which lies radius of diamond saw blade is more intensive than other place of it. However, the attenuation time (1.0s or so) of damping saw blade is much faster than it of diamond saw blade without damping (15s or so).
In addition, the influence of interlayer thickness on effect of noise reduction is be researched. We determine the most optimized interlayer thickness (0. 10mm) through experiment. On the cutting conditions without spraying water damping, the cutting noise of damping diamond saw blade is 86.69dB, it is 17.81dB smaller than it of ordinary diamond saw blade, which conforms with requirement of industry hygiene standard (90dB).
首先合理地设计了金刚石锯片的基体结构。试验出合理的基体连接工艺，并成功地制备出具有消音功能的金刚石锯片的基体。采用双面点焊的方式，熔焊面积为25％左右。该结构设计的消音机理为：层与层之间存在一层非常薄的空气层，形成不同金属与空气的多层结构，即A金属-空气-B金属-空气-A金属或A金属-空气-B金属-空气-B金属-空气-A金属等多层结构。当金刚石工具在切割激励的条件下，基体之间的空气层在振动的作用下来回地流动，由于夹层中间的空气流动，吸收了一部分振动能量，从而导致较低的噪声辐射。由于不同物质的固有振动频率不同，振动在不同物质间传播时，振动会降低，由振动产生的噪声也会降低。此外，由于夹层B为高塑性金属，振动使其内部的位错产生滑移和攀移，以消耗部分振动能，也是降低噪声的原因之一。
采用敲击噪声测试，确定了在锯片的外三分之一处振动最为强烈，同时消音锯片的噪声衰减仅为1.0秒左右，比普通金刚石锯片(15秒左右)快得多。
另外，本文还研究了夹层厚度对降噪效果的影响，通过试验确定了最合理的夹层厚度为0.10毫米。通过现场切割噪音测试，在干切的条件下，该消音结构的金刚石锯片切割噪声为86.69dB，而普通金刚石锯片的噪声为104.5dB，比普通锯片的噪声降低了17.81dB。达到了我国《工业企业卫生标准》中规定的90dB的要求。
Diamond saw blade is a tool which is widely used in cutting hard brittle materials, such as stone, concrete, glass, crystal, graphite electrode and so on. At the same time, the cutting noise usually outstrips 105dB while cutting. The noise pollution badly jeopardizes the health of the operating workers.
Matrix structure of diamond saw blade was designed rationally. Through experiment, rational joint technology was defined and matrix of diamond saw blade with noise damping was prepared. Matrix was jointed by two-sided spot welding, and welding area is 25% or so of matrix. Mechanics on noise reduction of the structure is as followed: There is a very thin air layers between the matrix, so the structure of multi-layer is formed. That is metal A-air-metal B-air-metal A or metal A-air-metal B-air-metal B-air-metal A. On the cutting motivation conditions, air layer between two metal layers is flowed to-and-fro, which can absorb a part of motivation energy, so it leads to low noise radiation. In addition, Because of different matter with different natural frequency, vibration of saw blade will weaken, when it transmits in the different matter. So the noise will be reduced. At last, vibration can make dislocation of metal slip and climb, which dissipate the vibration energy to reduce noise while cutting.
Through noise testing, we draw a conclusion that vibration of outer 1/3 which lies radius of diamond saw blade is more intensive than other place of it. However, the attenuation time (1.0s or so) of damping saw blade is much faster than it of diamond saw blade without damping (15s or so).
In addition, the influence of interlayer thickness on effect of noise reduction is be researched. We determine the most optimized interlayer thickness (0. 10mm) through experiment. On the cutting conditions without spraying water damping, the cutting noise of damping diamond saw blade is 86.69dB, it is 17.81dB smaller than it of ordinary diamond saw blade, which conforms with requirement of industry hygiene standard (90dB).
引文
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[6]何艳艳，唐霞辉．消音型金刚石圆锯片的研究动态．金刚石与磨料磨具工程，2000．3，(123)：12～15
[7]冯祖宾，冯海洲．消音金刚石锯片的研制．金刚石与磨料磨具工程，1994．4，(112)：2～4
[8]R.M. Slone and J.E. Robertson, investigation of Aerodynamic Noise from Circular Saw Blades, National Noise and Vibration Control Conference, Atlanta, Georgia, 1975:121～124
[9]Korkan, Experimental Investigation of Aerodynamic Noise from a Circular Saw Blade, National Noise and Vibration Control Conference, Chicago, 1977:190～195
[10]J. Stewart Investigation of Aerodynamic Noise Generation Mechanism of Circular Saw Blades, Noise Control Engineering Journal, 1978, (1):5～11
[11]胡映宁，王成勇，魏昕．金刚石圆锯片基体及锯齿结构的特性分析(二)．工具技术，2001，vol35，(8)：10～15
[12]Miguel Fernandez Gonzalez, Noise Reduction of Circular Saw Blades, Proceedings of Inter-Noise 79,1979, 321～323
[13]马建敏，吕景林．大型冷锯机噪声控制技术的试验研究．钢铁，2000．35(2)：62～63
[14]P.D. Wheeler, W.I. Acton, Wood Radiated Noise from Woodworking Machines, 9th ICA, Madrid, 1977
[15]张纪锁，王太勇．各种结构金属园锯片振型的试验分析．噪声与振动控制，1988(1)：25～27
[16]C. D. Mote, Free Vibration of Initially Stressed Circular Disks. Transactions of the ASME, 1965
[17]M. F. De Vries, et al. ON THE REDUCTION OF NOISE IN CIRCULAR SAWING. Alberta Research Council, Information Series North Am Metalwork Res. Conf, 2nd,Proc May 20-22,1974:22～34
[18]R. F. Keltie, W. F. REITER. DIMENSIONAL ANALYSIS AND SCALING OF THE AERODYNAMIC NOISE PRODUCED BY IDLING CIRCULAR SAW BLADES. American Society of Mechanical Engineers (paper) Dec 5, 1976:12
[19]M. S. Bobeczko, B. B. Henry. NOISE REDUCTON ACHIEVED WITH SLOTTED BALDES. Light Metal Age, 1976, 33: 9～10
[20]K. Niemiec. SAW BLADE DAMPING AND NOISE REDUCTON. Int. Conf on Noise Control Eng, Inter-noise'76, Proc Apr5-7,1976:25～30
[21]K. Hayasaka et al. Investigation on generation of vibration and noise of diamond circular saw blades. Journal of the Japan Society for Precision Engineering. 1993,59(12):2032～2036
[22]D.C.Stevenson, W.W.Gray, K.C.Hoong, Quietening Circular Saws by Reducing Blade Vibration, NOISE CONTROL ENGINEERING JOURNAL, 1989,vol33, (1):33～37
[23]A.Trochidis,Vibration Damping of Circular Saws, ACUSTICA, 1989,VOL69,:270～275
[24]H.k.Tonshoff, A. scherger, A bout Damping Mechanisms for Disk Shaped Tools, Annals of the CIRP Vol,1981:305～309
[25]冯祖宾，冯海洲．消音金刚石锯片的研制．金刚石与磨料磨具工程，1994．4(112)：2～4
[26]马建敏，吕景林．大型冷锯机噪声控制技术的试验研究．钢铁，2000．35(2)：60～63
[27]马建敏．旋转锯切噪声研究综述．噪声与振动控制，1999，(6)：33～37
[28]马建敏，吕景林．小型圆盘锯机锯切声功率的计算分析．西安理工大学学报，2000，16，(3)：248～251
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