Analysis of Stiffness Control and Vibration of Wire in Wiresaw Manufacturing Process

In this paper, we study the stiffness and vibration behaviors of wire in wiresaw manufacturing process. The result of stiffness control and vibration analysis can be used to predict and reduce the kerf loss during the wiresaw manufacturing process. In modeling stiffness, the wire is treated cis a wire stretched over a spherically bowed surface. The flexibility influence function (or the inverse of stiffness) of the wire under such geometry is studied. It is found that both the tension in the wire and geometry play important roles in the modeling of the stiffness of stretched wire in the wiresaw manufacturing process. The stiffness influence function is plotted and the results suggest control of stiffness through varying geometry and process parameters. Dynamically, the transverse vibration behavior of the axially moving wire is studied. The response under harmonic excitation is investigated with both closed-form and numerical method. The wire vibration is also simulated and plotted with three dimensional time history showing the vibration patterns of wire as a function of time.