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Experimental Study on Slicing Sapphire Crystal with Ultrasonic-Assisted Diamond Wire Saw
Faroug Ismael1,2, Pengfei Sun1, Yihe Liu1
1Key Laboratory of High Efficiency and Clean Mechanical Manufacture of Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan 250061, China.
Micromachines
|July 28, 2026
Summary
Ultrasonic-assisted diamond wire sawing (UADWS) improves sapphire slicing by optimizing parameters. Feed speed and wire speed are most critical for enhancing surface quality, reducing defects in sapphire crystal processing.
Area of Science:
- Materials Science
- Manufacturing Engineering
Background:
- Sapphire crystals are vital in engineering due to their exceptional properties like hardness and optical transparency.
- Slicing is a critical step impacting sapphire's final surface quality.
- Conventional wire sawing has limitations, while ultrasonic-assisted diamond wire sawing (UADWS) shows promise but requires further study.
Purpose of the Study:
- To investigate the impact of UADWS parameters on sapphire crystal surface quality.
- To identify the most influential parameters for optimizing sapphire slicing.
- To develop predictive models for surface roughness and waviness.
Main Methods:
- Conducted single-factor and orthogonal five-level experiments on UADWS parameters (amplitude, horn position, feed speed, wire speed).
- Evaluated surface quality using surface roughness (Ra) and waviness peak-valley (PV) difference.
- Performed range and variance analyses, and developed power regression models.
Main Results:
- Increasing feed speed and wire speed diminished ultrasonic assistance effectiveness.
- Application horn position had a minimal effect on surface quality.
- Orthogonal analysis revealed the order of influence: feed speed > wire speed > amplitude > application horn position.
Conclusions:
- Feed speed and wire speed are the most critical parameters for controlling sapphire surface quality during UADWS.
- Optimizing UADWS parameters, particularly feed and wire speed, can enhance sapphire surface quality and reduce post-processing needs.
- This study provides a foundation for optimizing UADWS processes for improved sapphire manufacturing.
