Process Parameters Analysis in Diamond Wire Saw Cutting NdFeB Magnet

Neodymium iron boron (NdFeB) magnetic materials are widely used in fields such as electronics, medical devices, power machinery, and hardware machinery. This paper conducted a three-factor and five-level orthogonal experiment on diamond wire saw cutting NdFeB to determine the influence degree of key factors such as workpiece feed rate, diamond wire speed, and workpiece processed size on the surface roughness <i>R</i>a and waviness <i>W</i>a of NdFeB slices. Further analysis was conducted on the influence of various parameters on the PV value (peak valley difference) of the waviness profile curve of the sawed surface. Finally, slicing processing was carried out under optimized process parameter combinations. The research results indicate that the primary and secondary order of process parameters affecting surface roughness <i>R</i>a and waviness <i>W</i>a is workpiece feed rate, wire speed, and sawed workpiece size, and the influence on the waviness PV value also shows a consistent trend. The optimal combination of processing parameters is workpiece feed rate of 0.1 mm·min^-1, wire speed of 1600 m·min^-1, and workpiece size of 10 mm. The obtained surface roughness <i>R</i>a is 0.433 μm and the waviness <i>W</i>a is 0.037 μm, respectively. The regression mathematical model for the waviness PV value is PV = 0.747 × <i>v</i>_s^-0.342 × <i>v_w</i>^0.546 × <i>L</i>^0.109. The research results of this paper provide an experimental basis and guidance for optimizing process parameters of sawing NdFeB.