Abstract Magnetic induction-free abrasive wire sawing is a hybrid process that introduces the high gradient magnetic field into traditional free abrasive wire sawing technology. A ferromagnetic saw wire is magnetized by the external uniform magnetic field, and it then generates a high gradient magnetic field around itself. Magnetic abrasive particles are attracted to the surface of the wire by the magnetic force, which leads to more abrasive particles in the sawing channel. This novel method effectively improves the utilizing rate of abrasive particles and is helpful to improve the wire sawing performance. In this study, the formation mechanism of the magnetic abrasive particle layer on the surface of saw wire is investigated theoretically and experimentally. Based on force analysis of the magnetic abrasive particle on the wire surface, a mathematical model for analyzing the formation mechanism of the magnetic abrasive particle layer is presented and studied by the numerical analysis software MATLAB. An experimental platform utilizing a high-speed camera is constructed to observe the formation of the magnetic abrasive particle layer on the wire. The experimental results reveal that the magnetized wire can adsorb lots of magnetic abrasive particles, thus leading to the formation of a magnetic abrasive particle layer. The shape of the magnetic abrasive particle layer approximates to an annular sector. Moreover, the thickness of the magnetic abrasive particle layer increases as the external uniform magnetic field strength increases. The experimental results verify the theoretical results. The present model is applied to study the formation mechanism of the magnetic abrasive particle layer on the surface of saw wire in magnetic induction-free abrasive wire sawing in detail.

中文翻译：

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无磁感应磨料线锯锯线表面磁性磨粒层形成机理研究

摘要 磁感应无磨料线锯是一种将高梯度磁场引入传统无磨料线锯技术的混合工艺。铁磁锯线被外部均匀磁场磁化，然后在自身周围产生高梯度磁场。磁性磨粒被磁力吸引到线材表面，导致锯切通道中产生更多的磨粒。这种新方法有效地提高了磨粒的利用率，有利于提高线锯性能。本研究从理论上和实验上研究了锯线表面磁性磨粒层的形成机理。基于磁性磨粒对线材表面的受力分析，提出了分析磁性磨粒层形成机理的数学模型，并利用数值分析软件MATLAB进行了研究。搭建了一个利用高速相机的实验平台来观察金属丝上磁性磨粒层的形成。实验结果表明，磁化线可以吸附大量的磁性磨粒，从而形成磁性磨粒层。磁性磨粒层的形状近似于扇形。此外，磁性磨粒层的厚度随着外部均匀磁场强度的增加而增加。实验结果验证了理论结果。