Diamond Wire Technology CS400 - Wire Tensioner Settings; Pulley Wear and Maintenance

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Table 2 – Tensioner Air Pressures
Table 2 – Tensioner Air Pressures
Wire
Diameter
Tensioner Air Pressure Wire Tension
(lbs)
Wire Tension
(N)
0.006” 0.150mm 10 psi 69 Kpa 2.1 lb 9.4 N
0.008” 0.200mm 15 psi 103 Kpa 3.1 lb 13.8 N
0.010” 0.250mm 20 psi 138 Kpa 4.2 lb 18.1 N
0.012” 0.300mm 25 psi 173 Kpa 5.2 lb 23.2 N
Pulleys
The pulleys wear out as the abrasive diamond wire cuts the pulley groove wider and deeper. There
are two types of pulley wear indicative of mechanical problems:
1. Eccentric wear results if a pulley does not rotate freely. The diamond wire cuts one portion of
the pulley groove deeper than another if the pulley sticks during part of its rotation. You
observe eccentric wear as an up and down motion of the wire when viewed from the side.
2. Flange wear results from misalignment between pulleys or misalignment between a pulley and
the capstan. The wire must always go into the pulley groove parallel to the sides of the pulley.
Flange wear appears as side-to-side flutter of the wire when viewed on edge. Misalignment
quickly erodes the pulley flange, and the wire could jump off the pulley.
If you run the wire drive unloaded and at high speed, you might notice wire vibration between the
pulleys. This type of vibration dampens out when the wire contacts the specimen.
Pulleys will eventually reach the end of their useful life even if the saw geometry is accurate. The
life of a pulley depends to some extent on the wire tension and the material you are cutting.