WO2015015411A1

WO2015015411A1 - Device, line and method for manufacturing tubular supports for the diamond beads of a cutting wire for stone material, and tubular support and cutting wire for stone material including said support

Info

Publication number: WO2015015411A1
Application number: PCT/IB2014/063507
Authority: WO
Inventors: Ilario Bidese
Original assignee: Individual
Current assignee: Individual
Priority date: 2013-07-29
Filing date: 2014-07-29
Publication date: 2015-02-05
Anticipated expiration: 2016-01-29
Also published as: ITVI20130192A1

Abstract

A method for manufacturing tubular supports (4) designed to support respective diamond outer members (3) to manufacture diamond beads (5) susceptible to be coupled to the flexible support structure (2) for manufacturing a wire (1) for cutting into slabs blocks of stone material. The method comprises the following steps: i) providing at least one metal tubular semifinished support (4') including two opposite ends (100', 100") to be finished; ii) finishing of the at least one metal tubular semifinished support (4') to obtain a finished tubular support (4). The finishing step ii) includes a step ii') of internal countersinking of the opposite ends (100', 100") of said at least one metal tubular semifinished support (4').

Description

DEVICE, LINE AND METHOD FOR MANUFACTURING TUBULAR SUPPORTS FOR THE DIAMOND BEADS OF A CUTTING WIRE FOR STONE MATERIAL, AND TUBULAR SUPPORT AND CUTTING WIRE FOR STONE MATERIAL INCLUDING SAID SUPPORT

DESCRIPTION

Field of the invention

The present invention is generally applicable in the technical field of the working of stone material, and in particular it relates to a method for manufacturing tubular supports for diamond beads of a cutting wire for blocks of stone material, such as stone, marble, concrete and the like.

The invention further relates to a tubular support obtainable by the above method.

The invention further relates to a machine for manufacturing such tubular supports.

The invention further relates to a line for the continuous manufacturing of such tubular supports.

The invention further relates to a method for manufacturing cutting wires including such tubular supports.

The invention further relates to a cutting wire including such tubular supports, as well as to a machine for cutting stone material including such wire.

State of the art

A great number of cutting wires for cutting blocks of stone material, such as stone, marble, concrete and the like are known. Such wires are generally wound on drums and pulleys, which are rotated so as to move in a tangential direction with respect to the wire and promote the penetration thereof through the stone material to be cut.

For example, cutting wires for stone material are known from JP9239721, DE3805405, JP3281118 and EP0718414.

WO02/04160 describes a wire comprising a support rope to which a plurality of bushings and a plurality of spacer elements in plastic material interposed between the bushings in order to keep them suitably mutually spaced are fixed. Each bushing has a hollow cylinder fastened to the support rope and a diamond annular peripheral element to cut the stone material.

Further, WO2012/052952 describes a wire for cutting stone material comprising a support rope provided with a plurality of diamond beads susceptible to interact with the stone material in order to cut it. Each diamond bead comprises a metal tubular support, externally to which an outer member in metal alloy and diamond powder is mounted. During the manufacturing of the wire, each section of the support rope free from the diamond beads is covered with at least one spacer element in polymeric material applied by hot molding and having the purpose to keep the mutual distance between the diamond beads.

The diamond beads of such cutting wires have cutting edges which, in the long run, may damage the support rope to which they are fastened. It is an object of the present invention to at least partially overcome the above mentioned drawbacks, by providing a method for manufacturing tubular supports for the diamond beads of a cutting wire of high efficiency and relative cheapness.

A particular object of the invention is to manufacture a wire with high wear resistance and allowing low maintenance.

A particular object of the invention is to manufacture low-cost tubular supports for the diamond beads of a cutting wire.

An object of the invention is to provide an economically advantageous method for manufacturing tubular supports for diamond beads of a cutting wire.

Another object of the invention is to obtain a method for manufacturing tubular supports for the diamond beads of a cutting wire which is relatively easy to implement and allows to manufacture wires with high level of construction quality.

Another particular object is to manufacture a wire having low levels of localized wear.

These and other objects, as better explained hereafter, are fulfilled by a method for manufacturing tubular supports for diamond beads of a cutting wire in accordance with what is herein described, claimed and/or shown.

The method is in particular useful for manufacturing tubular supports susceptible to support the respective diamond outer members to manufacture diamond beads susceptible to being coupled with a flexible support structure for the manufacturing of a wire for cutting into slabs of blocks of stone material.

The method may comprise sequentially the following steps: i) providing at least one metal tubular semifinished support including two opposite ends to be finished; and ii) finishing of the at least one metal tubular semifinished support to obtain a finished tubular support.

Suitably, the finishing step ii) includes a step of ii') internal countersinking of the opposite ends of the at least one metal tubular semifinished support.

Advantageously, the internal countersinking of the opposite ends is obtained by plastic deformation thereof.

In a preferred but non exclusive embodiment, the countersinking step ii') is carried out by at least one shaped hammer susceptible to come in contact with at least one of the opposite ends of the at least one metal tubular semifinished support.

The at least one shaped hammer may be movable between a rest position in which it is away from the respective end and a work position in which it is in contact therewith to plastically deform it, so as to obtain the internal countersinking.

Advantageously, each shaped hammer includes one respective substantially conical or frustoconical working surface susceptible to come in contact with the respective annular edge of the end of at least one metal tubular semifinished support. Conveniently, the latter and the working surface are susceptible to be mutually coaxial when each shaped hammer reach the work position.

Preferably, during the countersinking step ii') the outer diameter of the at least one metal tubular semifinished support is calibrated.

In a preferred but non exclusive embodiment, during the finishing step ii) the metal semifinished tubular support may comprise a plurality of receptacles susceptible to house the polymeric material of the spacer elements upon manufacturing the cutting wire.

According to another aspect of the invention, a machine and a line for manufacturing tubular supports for diamond beads of a cutting wire in accordance with what described, claimed and/or shown are provided.

According to another aspect of the invention, a tubular support and a cutting wire for stone material in accordance with what herein described, claimed and/or shown are provided.

Advantageous embodiments of the invention are described in accordance with the dependent claims.

Brief description of the drawings

Further features and advantages of the invention will appear more evident upon reading the detailed description of a preferred, non-exclusive embodiments of a method according to the invention and of some preferred embodiments of a wire 1 and of a machine 14 for cutting into slabs blocks B of stone material, which are described as non limiting examples with the help of the annexed drawings, in which:

FIG. 1 is a side view of some particulars of a wire 1;

FIG. 2 is a sectioned and enlarged view of some particulars of FIG.l;

FIG. 3 is an enlarged schematic view of a first example of laminar metal element 6 obtained in an intermediate step of the manufacturing process;

FIG. 4 is a schematic and enlarged view of a second example of laminar metal element 6 obtained in an intermediate step of the manufacturing process;

FIG. 5 is a schematic view of a machine 14 for cutting blocks B of stone material including the wire l;

FIG. 6 is a partially sectioned and enlarged view of some details of FIG.5;

FIG. 7 is a schematic view of an embodiment of semifinished supports 4' starting from a metal foil

13;

FIGS. 8, 9 and 10 are schematic views of some embodiments of the semifinished tubular supports

4';

FIG. 11 is a front view of an embodiment finished tubular supports 4;

FIG. 12 is a sectioned view of the embodiment of finished tubular support 4 of FIG.11 taken along a plane XII - XII;

FIGS. 13a and 13b are schematic views of a first embodiment of the finishing means 62, in which the shaped hammers 110', 110" are respectively in rest and in work position;

FIG. 14 is a sectioned view of some particulars of FIG.13a taken along a plane XIV - XIV;

FIGS. 15a to 15d are schematic views of a second embodiment of the finishing means 62, respectively in which the metal tubular semifinished element 4 is in correspondence to the hammer 110' and both the hammers 110', 110" are in rest position, the hammer 110' is in work position, the metal tubular semifinished element 4 is in correspondence to the hammer 110" and both the hammers 110', 110" are in rest position, the hammer 110" is in work position;

FIGS. 16a to 16d are schematic views of a third embodiment of finishing means 62, respectively in which the end 100' of the metal tubular semifinished elemtnt 4 faces the single hammer 110' and the latter is in rest position, the single hammer 110' is in work position, the metal tubular semifinshed element 4 is overturned and the end 100" of the metal tubular semifinished element 4 faces the single hammer 110' for the next manufacturing process.

Detailed description of some preferred embodiments

With reference to the above figures, a method and a machine are described for manufacturing tubular supports 4 susceptible to support a respective diamond outer members 3 to obtain diamond beads 5 susceptible to be coupled to a flexible support structure 2 for manufacturing a wire 1 for cutting blocks B of stone material, such as stone, marble, granite, concrete and the like.

In a per se known manner, the wire 1 can be manufactured by a method which comprises a first step 1) of providing a flexible support structure 2, which may be as a non-limiting example a cable or a rope made of metallic material, e.g. steel.

A second step 2) of providing a plurality of diamond beads 5 may be provided, each diamond bead 5 comprising in a per se manner a tubular support 4 and a diamond outer member 3.

Each outer member 3 is susceptible to interact with the stone material to cut it.

Each tubular support 4 may be susceptible to support a corresponding diamond outer member 3 and to be interposed between the latter and the flexible support structure 2. The diamond outer members 3 may be obtained in different ways, for example by sintering, and may include at least a part of its content derived from diamond or like material.

In a per se known manner, each diamond outer member 3 may be put externally to a corresponding tubular support 4, so as to obtain the diamond beads 5.

It is understood that for the purpose of manufacturing the wire 1 diamond beads 5 already assembled may be used without departing from the scope of protection defined by the annexed claims. In this case, the manufacturing method of the wire 1 may for example include a collection step of the diamond beads 5 already assembled from a storage site. The manufacturing method of the wire 1 may then include a subsequent step 3) of inserting the diamond beads 5 on the flexible support structure 2.

In particular, the diamond beads 5 may be positioned at predetermined mutual distances. By suitably choosing the distances between the diamond beads 5, free portions 8 of the flexible support structure 2 may be provided therebetween, that is portions of the latter flexible support structure 2 not occupied by the diamond beads 5.

A further step 4) may then be provided of manufacturing spacer elements 9 in thermoplastic polymeric material around the flexible support structure 2, for example by injection molding of polyurethane. More in detail, the spacer elements 9 may be injection molded externally to the flexible support structure 2 in correspondence to its free portions 8. In this manner, the spacer elements 9 interpose between the diamond beads 5 to mutually block them. In this step, the polymeric material interpose, inter alia, between the flexible support structure 2 and the tubular support 4.

Advantageously, the step 4) of manufacturing the spacer elements 9 may also include the molding of a layer 9' of polymeric material also externally to the diamond beads 5 already positioned on the flexible support structure.

Suitably, each of the tubular supports 4 may be manufactured by the sequence of steps described below.

A first step i) may comprise the provision of a metal semifinished tubular support 4' with two opposite ends 100', 100" to be finished, while a second step ii) may provide for its finishing to obtain the finished tubular support 4.

As used herein, the term "providing" and derivatives thereof designates the preparation of a relevant component for a relevant process step, including any preventive treatment designed for optimal performance of the step of interest, from simple collection and possible storage to thermal and/or chemical and/or physical pre-treatments or the like.

It is understood that, even though hereinafter it will be dealt with one single metal tubular semifinished support 4' and with one single tubular finished support 4, more metal semifinished tubular supports 4' may be provided, for example worked in series or in parallel, to obtain more finished tubular supports 4, without departing from the scope of protection defined by the annexed claims.

Advantageously, the finishing step ii) may include a step ii') of internal countersinking of the opposite ends 100', 100" of the metal tubular semifinished support 4'.

It is understood that the countersinking of the ends 100', 100" may be obtained by any technique or device, for example through a countersinking rotating tool of per se known type.

However, the countersinking of the ends 100', 100" may suitably be obtained by plastic deformation of the latter.

In the present document, the term "plastic deformation" and derivatives thereof indicates a deformation, either hot or cold type, that does not macroscopically disappear when a stress stops. For this reason, possible microscopic elastic or elasto-plastic returns do not have any effect. If, when a portion is under stress, it is not possible to observe a complete return to the originary shape, such portion is plastically deformed.

It is understood that the plastic deformation of the ends 100', 100" may be obtained through any technique, e.g. forming.

In a preferred but non-exclusive embodiment, represented for example in the FIGS 13a and 13b, the countersinking step ii') may be carried out by means of a pair of shaped hammers 110', 110" placed on opposite sides of the metal semifinished tubular support 4' and facing to the respective ends 100', 100" thereof.

Advantageously, each of the shaped hammers 110', 110" is movable between a rest position in which it is away from the respective end 100', 100" of the metal semifinished tubular support 4' and a work position in which it is in contact therewith to plastically deform it, so to obtain an internal countersinking.

The trajectory followed by the shaped hammers 110', 110" between the respective rest and work positions may be whichever. However, the shaped hammers 110', 110" may preferably slide along a longitudinal axis Y between the rest and working positions.

On the other hand, the shaped hammers 110', 110" may move in a mutually independent manner. However, in a preferred but non-exclusive embodiment, the shaped hammers 110', 110" may reach the work position at the same time. Advantageously, besides this, they may also reach the rest position at the same time.

Suitably, the shaped hammers 110', 110" may include respective working surfaces 111', 111" which are substantially conical or frustoconical and which are susceptible to come in contact with the respective end annular edges 10 , 101" of the metal semifinished tubular support 4'.

Advantageously, the metal semifinished tubular support 4' and the working surfaces 111', 111" may be mutually coaxial during the sliding of the shaped hammers 110', 110" from the rest position to the work position. On the other hand, the metal semifinished tubular support 4' and the working surfaces 111', 111" may be mutually coaxial during the sliding of the shaped hammers 110', 110" from the rest position to the working position along the longitudinal axis Y.

In a preferred but non-exclusive embodiment, the working surfaces 111', 111" may be substantially frustoconical, and each of the shaped hammers 110', 110" may include a respective elongated element 112', 112" defining a longitudinal axis, which may preferably coincide with the axis Y, encompassed by the respective working surface 111', 111".

Suitably, each of the elongated elements 112', 112" may include an outer surface 113', 113" susceptible to come in contact with the inner wall 12 of the metal tubular semifinished support 4' when the shaped hammers 110', 110" reach the work position.

Preferably, the outer surface 113', 113" of the elongated elements 112', 112" may include a plurality of longitudinal ridges 114', 114" susceptible to manufacture respective longitudinal channels 41 on the inner wall 12 of the metal semifinished tubular support 4' when the shaped hammers 110', 110" reach the working position.

It is understood that the metal semifinished tubular support 4' during the finishing step ii) may be internally flat or having grooves or cavities 11 on the inner wall 12 without for this reason departing from the scope of protection defined by the annexed claims. In other words, if the shaped hammers 110', 110" include the longitudinal ridges 114', 114" the metal finished tubular support 4 may include only longitudinal channels 41 or may include both longitudinal channels 41 and grooves or cavities 11, as shown in FIG. 12.

The longitudinal channels 41 are susceptible to housing the polymeric material of the spacer elements 9.

Preferably, during the finishing step ii) the metal tubular semifinished supports 4' may comprise a plurality of receptacles 11' susceptible to house the polymeric material of the spacer elements 9 during the manufacturing of the cutting wire 1.

In another embodiment, shown in the FIGS. 15a to 15d, the finishing step ii) may be carried out with the two hammers 110', 110' not aligned along one single axis. Therefore, each of the hammers 110', 110' defines a respective axis Y, Y', along which it can slide between the respective rest and working positions.

In such embodiment, the internal countersinking of the ends 100', 100" can occur sequentially. In particular, at first the end 100' is worked by means of the hammer 110' and then, after moving the metal tubular semifinished support 4' until putting the end 100" in correspondence to the hammer 110", by means of the latter.

In a further embodiment, shown in the FIGS. 16a to 16d, the finishing step ii) may be carried out by means of one single hammer 110', which first works the end 100' and then the opposite end 100". Between the two countersinking steps it is necessary to overturn the metal semifinished tubular support 4', as shown in FIG. 16c.

Preferably, the above described finishing step ii) can be carried out by a suitable machine 200 including a support frame with a seat 210 to support the metal tubular semifinished support 4' and finishing means 62, which may include the single hammer 110' or the pair of aligned or not aligned hammers 110', 110", as described above.

Regardless of the configuration of the finishing means 62, the seat 210 can be defined by the jaws 220 of a clamp, so that during the countersinking the outer diameter of the metal semifinished tubular support 4' is calibrated. For this purpose, the jaws 220 may have an internal portion with a substantially cylindrical shape, with an internal diameter D equal to the desired external diameter of the finished tubular support 4.

In fact, the axial mechanical stresses caused by the single hammer 110' or by the pair of hammers 110', 110" tend to deform the metal semifinished tubular support 4' in a radial direction. However, the jaws 220 limit such deformations, allowing to obtain a final product with standardized and defined geometry.

The step i) of provision of the metal semifinished tubular support 4' can take place in any manner. For example, the metal semifinished tubular support 4' can be obtained from a continuous metal bar, suitably cut at the required length and then threaded so as to obtain cavities on the internal surface thereof, which cavities being susceptible to house the polymeric material of the spacer elements 9.

However, the step i) of provision of the metal semifinished tubular support 4' may preferably occur in accordance with the teaching of the international patent application WO2014/013450.

In particular, the step i) of provision of the metal semifinished tubular support 4' may include a step i') of providing a metal foil 13, which can be substantially flat and have an elongated shape defining a longitudinal axis X, which shape being generally rectangular. The metal foil 13 can include a pair of edges 7, T on opposite sides with respect to the longitudinal axis X.

It is understood that even though the present invention deals only with one single foil 13, more metal foils can be provided, for example placed in series or in parallel, without departing from the scope of protection defined by the annexed claims.

The step i) of provision of a metal foil 13 may include the unwinding thereof from a reel 60 on which it is wound.

The step i) of provision of a metal foil 13 may further include a step i") of grinding the edges 7, T by suitable grinding means 57, for example a pair of grinding cylinders or a pair of grinding tools or a pair of grinding machines. In this way, the edges 7, T become mutually complementary shaped, for example having a substantially rectilinear or any curvilinear form, provided that the edges 7, T are complementary shaped.

Although in the present description it is assumed that the step i") of grinding the edges 7, T takes place subsequently to the unwinding of the metal foil 13 from the reel 60 on which it is wound, it is understood that the grinding step, if any, may be done at any time of the process, provided that it is accomplished before the joining step of the edges 7, 7', without departing from the scope of protection defined by the appended claims.

Suitably, the step i) of providing the metal foil 13 may further comprise a step i"'") of providing on its operative face 10 a plurality of grooves or recesses 11 by suitable means 53 for manufacturing thereof. For example, the manufacturing means 53 of the grooves and/or recesses 11 on the operative face 10 may include a knurling device, so as to obtain a knurl thereon. As used herein, the term "grooves" or derivatives thereof means an elongated aperture, of any size.

As used herein, the term "recesses" or derivative thereof means a recessed or empty portion of the relevant surface, of any shape or size, provided they it has is not an elongated shape.

FIG. 8 shows an example of metal semifinished tubular support 4' manufactured by a matal foil

13 which includes exclusively grooves 11, in the form of a knurl.

FIG. 9 shows an example of a tubular support 4 manufactured by means of a metallic foil 13 that includes only recesses 11, in the form of hexagonal openings.

FIG. 10 shows an example of a tubular support 4 manufactured by means of a metallic foil 13 which includes both recesses and grooves 11.

The grooves and/or recesses 11 may be manufactured in any manner on the operative face 10. For example, they may be made by sandblasting of the operative face 10 or by treatment thereof with an acid, so as to roughen the same operative face 10.

Alternatively, the grooves and/or recesses 11 may already be provided on the operative face 10 of the metal foil 13, as for example previously made or otherwise originally present thereon.

In any case, upon the next bending step i") the metal foil 13 includes the operative face 10 with the grooves and/or recesses 11.

Subsequently to the first step i'), a second step i") may take place of bending the metal foil 13 around the axis X up to the reciprocal matching of the complementary shaped edges 7, 7'.

To this end, suitable bending means 54 may be provided, for example a bending machine for metal sheet, shown in FIG. 8 with a dotted line.

Advantageously, the step ii) may be accomplished by bending the metal foil 13 in correspondence of the operative face 10 provided with grooves and/or recesses 11, so that the latter defines the inner wall 12 of the tubular support 4.

This way, the grooves and/or recesses 11 may be manufactured on the inner wall 12 of the tubular support 4, so as to define a plurality of receptacles 11' susceptible to house the polymeric material of the spacer elements 9 during the above step 4) of manufacturing thereof, for example by injection molding of polyurethane.

If the operative face 10 includes only grooves 11, the receptacles 11' on the inner wall 12 of each tubular support 4 are annular shaped.

In this case, in order to prevent the diamond beads 5 from sliding along the flexible support structure 2 upon the interaction thereof with the block B to be cut, the annular receptacles 11' may be non-parallel to the axis X and mutually spaced apart and disconnected so as not to define a helical pattern.

In particular, the grooves 11 may mainly extend along one or more directions inclined with respect to the axis X.

Suitably, the grooves 11 may further have direction substantially orthogonal to the axis R, as shown in FIG. 4. In this way, the direction of the grooves 11 does not impart a motion to the tubular support 4 upon the interaction with the flexible support structure 2 during use.

Therefore, the prevalent direction of the grooves 11 allows to obtain a substantial reduction of the movement of the diamond beads 5 along the flexible support structure 2, giving the wire 1 high resistance to wear and, more in general, greater duration.

Subsequently to the bending step i " ) , a third step i'") may take place of permanently joining the complementary shaped edges 7, T so as to obtain the tubular support 4.

Suitably, the permanent joining step i'") of the complementary shaped edges 7 may be accomplished by welding or hot or cold pressure bonding.

For this purpose, suitable means 55 for permanently joining the edges 7, T may be provided, which may include for example a welding or bonding device.

This way, a semifinished metal tube 4' may be obtained, which has substantially the same length of the metal foil 13 and may define an axis X' substantially parallel to the longitudinal axis X thereof.

Suitably, to correct any deformation due to the permanent joining step i'"), a step may be provided of calibration of the diameter of the semifinished metal tube 4'. For this purpose, suitable calibration means 59 may be provided, which may include for example a drawing device.

Subsequently to the permanent joining step i'"), a fourth step i"") may take place of cutting of the semifinished metal tube 4" in order to obtain the tubular supports 4'. For this purpose, suitable cutting means 61, may be provided, for example a disc or water cutting device.

Suitably, subsequently to the step i"") a step ii) may take place of finishing of the semifinished tubular elements 4'. To this end, the semifinished tubular elements 4' from the outlet 56 from the cutting means 61 may be fed to the machine200, as shown in FIG. 7.

In a preferred but non-exclusive embodiment, for each metal foil 13 on the reel 60 all the above steps may take place continuously.

In particular, the step i') of providing the metallic foil 13, the step i") of bending thereof and the step i'") of permanent joining the edges 7, T may advantageously take place sequentially in continuous.

Suitably, also the step i"") of cutting the metal semifinished tubular support 4" to obtain the semifinished tubular supports 4' may take place in continuous after the step i'") of permanent joining of the edges 7, T.

For this purpose, suitable means may be provided to continuously feed the metal foil 13 from the reel 60 to a production line extending from the inlet 51 of the folding means 54 to the outlet 230 of the machine for the finishing 200, via the grinding means 57, the manufacturing means 53 for the grooves and/or recesses 11, the permanent joining means 55, the calibration means 59 and the cutting means 61.

These continuous feeding means, not represented in the figures as per se known, may include conveyor belts and/or rollers, motorized or driven. Carrier means of the metallic foil 13 through the various stations of the apparatus may further be provided.

The process may further be inherently continuous without departing from the scope of protection defined by the appended claims. In other words, only some steps may be accomplished sequentially in continuous, whereas other steps may be accomplished singularly.

For example, the step i') of providing the metallic foil 13, the bending step i") thereof and the third step i'") of permanently joining the edges 7, T may take place sequentially in continuous. In this case, the semifinished metal tube 4' at the outlet of the permanent joining means 55 may be wound on a special reel and stored for the next cutting step iv) thereof, which may for example take place in another section of the apparatus or in another apparatus separate from the one in which the first three steps have been accomplished, or further in the same apparatus but the next day.

It is self-evident that in any case the length of the starting metal foil 13 is greatly higher than that of the semifinished tubular supports 4', for example in a ratio 100:1 or more.

As used herein, the term "length greatly higher" and derivatives therof means a ratio between the lengths of at least 30:1.

In view of the foregoing, it is possible to minimize the time and cost of production of the tubular supports 4.

In fact, the production process of the finished tubular support 4 may be accomplished in a substantially continuous manner, with apparent advantages when compared to the production processes of the prior art.

Thereafter, a wire 1 for cutting blocks B of stone material is described, which may be preferably be manufactured by the above method. The wire 1 may comprise a flexible support structure 2 defining an axis L and a plurality of diamond beads 5 inserted on the flexible support structure 2.

Each diamond bead 5 may include a tubular support 4 and a cutting member 3 iin diamond material externally coupled to the tubular support 4 and susceptible to interact with the stone to cut it.

Each tubular support 4 may have one pair of mutually complementary shaped edges 7, T joined by a permanent joining, for example a weld or a bonding bead, and may have an inner wall 12 with the above described receptacles 11'.

The diamond beads 5 may be positioned on the flexible support structure 2 at predetermined mutual distances. The wire 1 may further comprise a plurality of spacer elements 9 in thermoplastic polymeric material, for example polyurethane, injection-molded between the diamond beads 5 to mutually block them. As shown in FIG. 5, a machine 14 for cutting blocks of stone material B may comprise a frame 15, preferably of the portal-like type, at least one wire 1 for the cutting the blocks B and at least one pair of devices 16 mounted on the frame 15 for supporting and moving the wire 1, for example drums and/or pulleys.

The wire 1 may be obtained by the above described method and/or apparatus. The machine 14 may have a plurality of wires 1 mounted on respective supporting and moving devices 16 so as to be substantially parallel to each other, thus allowing the cut into slabs of the blocks B of stone material.

The invention is susceptible to many changes and variants, without departing from the annexed claims. All the particulars may be replaced by other technically equivalent elements, and the materials may be different according to the needs, without exceeding the scope of protection of the invention.

Claims

1. A method for manufacturing tubular supports (4) designed to support respective diamond outer members (3) to obtain diamond beads (5) to be coupled to a flexible support structure (2) for manufacturing a cutting wire (1) for cutting slabs from blocks of stone material, the method comprising in sequence the following steps:

i) providing at least one metal tubular semifinished support (4') including two opposite ends (100', 100") to be finished;

ii) finishing of said at least one metal tubular semifinished support (4') to obtain a finished tubular support (4);

wherein such finishing step ii) includes a step ii') of internal countersinking of said opposite ends

(100', 100") of said at least one metal tubular semifinished support (4').

2. Method according to claim 1, wherein the internal countersinking of said opposite ends (100', 100") is obtained by plastic deformation thereof.

3. Method according to the preceding claim, wherein said countersinking step ii') is carried out by at least one shaped hammer (110', 110") designed to come in contact with at least one of said opposite ends (100', 100") of said at least one metal tubular semifinished support (4'), said at least one shaped hammer (110', 110") being movable between a rest position in which it is away from the respective end (100', 100") and a working position in which it is in contact therewith (100', 100") to plastically deform it, so as to obtain the internal countersinking.

4. Method according to the preceding claim, wherein said countersinking step ii') is carried out by one single shaped hammer (110', 110") designed to come in contact first with one of said opposite ends (100', 100") of said at least one metal tubular semifinished support (4') and subsequently with the other of said opposite ends (100', 100").

5. Method according to claim 3, wherein said countersinking step ii') is carried out by a pair of shaped hammers (110', 110") each designed to come in contact with a respective opposite end (100', 100") of said at least one metal tubular semifinished support (4'), each of said shaped hammers (110', 110") being movable between a rest position in which it is away from the respective end (100', 100") of said at least one metal tubular semifinished support (4') and a respective working position in which it is in contact therewith (100', 100") to plastically deform it, so as to obtain the internal countersinking.

6. Method according to the preceding claim, wherein said shaped hammers (110', 110") are placed at opposite sides of said at least one metal tubular semifinished support (4') and are facing the respective ends (100', 100") thereof (4').

7. Method according to the preceding claim, wherein both said shaped hammers (110', 110") reach the work position simultaneously.

8. Method according to any one of the claims 3 to 7, wherein each shaped hammer (110', 110") includes a respective substantially conical or frustoconical working surface (111', 111") designed to come in contact with the respective annular edge (10 , 101") of the ends (100', 100") of said at least one metal tubular semifinished support (4'), the latter (4') and said working surface (111', 111") being mutually coaxial when each shaped hammer (110', 110") reach said work position.

9. Method according to claims 5 and 8 or 6 and 8 or 7 and 8, wherein the working surfaces

(11 , 111") of both shaped hammers (110', 110") of said pair are substantially equal each other.

10. Method according to any one of the claims 3 to 9, wherein each shaped hammer (110', 110") slides along a longitudinal axis (Y, Y') between said rest and work positions, said at least one metal tubular semifinished support (4') and said working surface (111', 111") of each shaped hammer (110', 110") being mutually coaxial during the sliding of each shaped hammer (110', 110") from the rest position to the work position along said longitudinal axis (Y, Y').

11. Method according to claims 5 and 10 or 6 and 10 or 7 and 10, wherein both the shaped hammers (110', 110") of said pair slide along one single longitudinal axis (Y), said at least one metal tubular semifinished support (4') and both the working surfaces (111', 111") of the shaped hammers (110', 110") of said pair being mutually coaxial during the sliding of the latter (110', 110") from the rest position to the work position along said longitudinal axis (Y).

12. Method according to any one of the claims 8 to 11, wherein said working surface (111', 111") of each shaped hammer (110', 110") has a substantially frustoconical shape, each of said shaped hammers (110', 110") including a respective elongated element (112', 112") defining a longitudinal axis (Υ', Y") encompassed by the respective working surface (111', 111"), each elongated element (112', 112") including an outer surface (113', 113") designed to come in contact with the inner wall (12) of said at least one metal tubular semifinished support (4') when said shaped hammers (110', 110") reach said work position.

13. Method according to the preceding claim, wherein the outer surface (113', 113") of each elongated element (112', 112") includes a plurality of longitudinal ridges (114', 114") designed to manufacture longitudinal recesses (41) on the inner wall (12) of said at least one metal tubular semifinished support (4') when said shaped hammers (110', 110") reach said working position.

14. Method according to claims 5 and 13 or 6 and 13 or 7 and 13, wherein the shaped hammers (110', 110") are mutually dimensioned so that when the latter (110', 110") reach the work position said longitudinal ridges (114', 114") manufacture substantially continuous longitudinal recesses (41) along said internal wall (12) of said at least one metal tubular semifinished support (4').

15. Method according to one or more preceding claims, wherein during the countersinking step ii') the outer diameter of said at least one metal tubular semifinished support (4') is calibrated.

16. Method according to claims 3 and 15, wherein said metal tubular semifinished support (4') in inserted in a pair of jaws (220) before said at least one shaped hammer (110', 110") reach said working position.

17. Method according to claim 5 and 16 or 6 and 16 or 7 and 16, wherein said metal tubular semifinished support (4') is inserted in said jaws (220) before at least one of the shaped hammers (110', 110") of said pair reaches the work position, respectively both the shaped hammers (110', 110") of said pair reach the work position.

18. Method according to one or more of the preceding claims, wherein the cutting wire (1) is designed to further include spacer elements (9) in polymeric material to be interposed between the flexible support structure (2) and the diamond beads (5) to mutually block them, wherein upon said finishing step ii) said at least one metal tubular semifinished support (4') comprises a plurality of receptacles (1 ) designed to house the polymeric material of the spacer elements (9) upon the manufacturing of the cutting wire (1).

19. Method according to one or more of the preceding claims, wherein said step i) of proving at least one metal tubular semifinished support (4') comprises the following steps:

i') providing at least one metal foil (13) defining a longitudinal axis (X), said at least one metal foil (13) including one pair of edges (7, 7') at opposite ends with respect to said axis (X);

i") bending said at least one metal foil (13) around said axis (X) up to the reciprocal matching of said edges (7, 7');

i'") welding or bonding of said edges (7, 7') to obtain a metal semifinished tube (4");

i"") cutting said semifinished metal tube (4") to obtain the tubular supports (4'); wherein upon said bending step i") said at least one metal foil (13) includes at least one operative face (10) having a plurality of grooves and/or recesses (11) spaced apart each other, said bending step i") being carried out so that said operative face (10) provided with said grooves and/or cavities (11) defines the inner wall (12) of said at least one metal tubular semifinished support (4');

wherein said grooves and/or cavities (11) are manufactured so as to define a plurality of receptacles (1 ) designed to house the polymeric material of the spacer elements (9) during the manufacturing of the cutting wire (1).

20. Method according to the preceding claim, wherein said step i') of providing said metal foil (13) comprises a step \""') of manufacturing on said operative face (10) said grooves and/or cavities (11) which is accomplished by knurling a knurl on said operative face (10).

21. A machine for finishing said metal tubular semifinished supports (4') to obtain finished tubular supports (4) designed to support respective diamond outer members (3) to manufacture diamond beads (5) to be coupled to a flexible support structure (2) for manufacturing a wire (1) for cutting slabs from blocks of stone material, the machine comprising:

- at least one seat (210) for at least one metal tubular semifinished support (4') including two opposite ends (100', 100") to be finished; and - means (62) for finishing said at least one metal tubular semifinished support (4') to obtain one tubular finished support (4);

wherein said finishing means (62) include at least one shaped hammer (110', 110") designed to come in contact with one of said opposite ends (100', 100") of said at least one metal tubular semifinished support (4'), said at least one shaped hammer (110', 110") being movable between a rest position in which it is away from the respective end (100', 100") and a work position in which it is in contact therewith (100', 100") to plastically deform it, so as to obtain an internal countersinking thereof.

22. Machine according to the preceding claim, wherein said finishing means (62) comprise one single shaped hammer (110', 110") designed to come in contact first with one of said opposite ends (100', 100") of said at least one metal tubular semifinished support (4') and then with the other of the said opposite ends (100', 100").

23. Machine according to claim 21, wherein said finishing means (62) comprise a pair of shaped hammers (110', 110") each designed to come in contact with the respective opposite end (100', 100") of said at least one metal tubular semifinished support (4'), each of said shaped hammers (110', 110") being movable between a respective rest position in which it is away from the respective end (100', 100") of said at least one metal tubular semifinished support (4') and a respective work position in which it is in contact therewith (100', 100") in order to plastically deform it, so as to obtain the internal countersinking.

24. Machine according to the preceding claim, wherein said shaped hammers (110', 110") are positioned at opposite sides of at least one seat (210) for said at least one metal tubular semifinished support (4') and are facing the respective ends (100', 100") thereof (4').

25. Machine according to the preceding claim, further comprising control means acting on said shaped hammers (110', 110") so that they reach the work position simultaneously.

26. Machine according to any one of the claims 21 to 25, wherein each shaped hammer (110', 110") comprise a respective substantially conical or frustoconical working surface (111', 111") designed to come in contact with the respective annular edge (10 , 101") of the ends (100', 100") of said at least one metal tubular semifinished support (4'), the latter (4') and said work surface (111', 111") being mutually coaxial when each shaped hammer (110', 110") reaches said work position.

27. Machine according to claims 23 and 26 or 24 and 26 or 25 and 26, wherein the work surfaces (11 , 111") of both shaped hammers (110', 110") of said pair are substantially equal each other.

28. Machine according to any one of the claims 21 to 27, wherein each shaped hammer (110',

110") slides along a respective longitudinal axis (Y, Y') between said rest and work positions, said at least one metal tubular semifinished support (4') and the working surface (111', 111") of each shaped hammer (110', 110") being mutually coaxial during the sliding of each shaped hammer (110', 110") from the rest position to the work position along said longitudinal axis (Y).

29. Machine according to the claims 23 and 28 or 24 and 28 or 25 and 28, wherein both the shaped hammers (110', 110") of said pair slide along one single longitudinal axis (Y), said at least one metal tubular semifinished support (4') and both the working surfaces (111', 111") of the shaped hammers (110', 110") of said pair being mutually coaxial during the sliding of the latter (110', 110") from the rest position to the work position along said longitudinal axis (Y).

30. Machine according to any one of the claims 26 to 29, wherein the work surface (111', 111") of each shaped hammer (110', 110") has a substantially frustoconical shape, each shaped hammer (110', 110") including a respective elongated element (112', 112") defining a longitudinal axis (Υ', Y") encompassed by the respective work surface (111', 111"), each elongated element (112', 112") including an outer surface (113', 113") designed to come in contact with the inner wall (12) of said at least one metal tubular semifinished support (4') when each shaped hammer (110', 110") reaches said work position.

31. Machine according to the preceding claim, wherein the outer surface (113', 113") of each elongated element (112', 112") comprises a plurality of longitudinal ridges (114', 114") designed to manufacture longitudinal channels (41) on the inner wall (12) of said at least one metal tubular semifinished support (4') when each shaped hammer (110', 110") reaches said work position.

32. Machine according to claims 23 and 31 or 24 and 31 or 25 and 31, wherein the shaped hammers (110', 110") are mutually dimensioned so that when the latter (110', 110") reach the working position, said longitudinal ridges (114', 114") manufacture substantially continuous longitudinal channels (41) along the entire length of the inner wall (12) of said at least one metal tubular semifinished support (4').

33. Machine according to one or more of the claims 21 to 32, wherein said seat (210) is defined by a pair of jaws (220), so that when the countersinking of said at least one metal tubular semifinished support (4') is carried out by said at least one shaped hammer (110', 110"), respectively by said shaped hammers (110', 110"), the outer diameter of the same at least one metal tubular semifinished support (4') is calibrated.

34. A line for manufacturing in continuous tubular supports (4) designed to support respective diamond outer members (3) to manufacture diamond beads (5) to be coupled to a flexible support structure (2) for manufacturing a wire (1) for cutting slabs from blocks of stone material, the apparatus comprising in sequence:

- an inlet (56) for at least one metal tubular semifinished support (4') including two opposite ends (100', 100") to be finished;

at least one machine (200) for finishing said at least one metal tubular semifinished support (4') according to any one of the claims 21 to 33;

an outlet (230) for the finished metal supports (4).

35. Line according to the preceding claim, wherein upstream of said inlet (56) for said at least one metal tubular semifinished support (4') the line comprises in sequence:

an inlet (51) for at least one metal foil (13) defining a longitudinal axis (X), said at least one metal foil (13) including a pair of edges (7) positioned at opposite ends with respect to said axis (X);

- means (54) for bending said at least one metal foil (13) around said axis (X) up to the reciprocal matching of said edges (7);

means (55) for permanently joining said edges (7), in said a manner to obtain a semifinished metal tube (4');

means (61) for cutting said semifinished metal tube (4') so as to obtain a metal tubular semifinished support (4');

an outlet (56) for said metal tubular semifinished support (4');

wherein upstream of the inlet of said bending means (54) said at least one metal foil (13) includes at least one operative face (10) having a plurality of grooves and/or recesses (11) spaced apart each other, said bending means (54) being configured in said a manner that said operative face (10) provided with said grooves and/or recesses (11) defines the inner wall (12) of the tubular support (4);

wherein said grooves and/or recesses (11) are manufactured so as to define a plurality of receptacles (1 ) designed to house the polymeric material of the spacer elements (9) upon manufacturing of the cutting wire (1).

36. Line according to the preceding claim, further comprising means (53) for manufacturing on said operative face (10) of said at least one metal foil (13) said grooves and/or recesses (11).

37. Line according to the preceding claim, wherein said manufacturing means (53) of said grooves and/or cavities (11) include a knurling device so as to obtain on said operative face (10) a knurl.

38. A tubular support (4) obtainable by the method according to one or more of the claims 1 to 20 or by the machine according to one or more of the claims 21 to 33 or by the line according to one or more of the claims 34 to 37, the tubular support (4) being designed to support respective diamond outer members (3) to manufacture diamond beads (5) to be coupled to a flexible support structure (2) for manufacturing a wire (1) for cutting into slabs blocks of stone material, the tubular support (4) including two opposite ends (100', 100") plastically deformed by means of at least one shaped hammer (110', 110").

39. Tubular support according to the preceding claim, wherein the cutting wire (1) is designed to further include spacer elements (9) in polymeric material designed to interpose between the flexible support structure (2) and the diamond beads (5) to mutually block them, wherein said tubular support (4) comprises an inner wall (12) with a plurality of receptacles (11') designed to house the polymeric material of the spacer elements (9) when the cutting wire (1) is manufactured.

40. Tubular support according to claim 38 or 39, wherein said receptacles (1 ) are radial receptacles, wherein said tubular support (4) further comprises one or more axial longitudinal receptacles (41) on the inner wall (12).

41. A wire for cutting into slabs blocks of stone material, comprising:

a) a flexible support structure (2);

b) a plurality of diamond beads (5) inserted on said flexible support structure (2), each of said diamond beads (5) including one tubular support (4) and a diamond outer member (3) coupled externally to said tubular support (4) and designed to interact with the stone material to cut it;

c) a plurality of spacer elements (9) in polymeric material interposed between the flexible support structure (2) and said diamond beads (5) to mutually block them;

wherein each of said tubular supports (4) is the tubular support according to any one of the claims 38 to 40.

42. A machine for cutting into slabs blocks of stone material, comprising a frame (15), at least one cutting wire (1) and at least one pair of devices (16) mounted on said framework (15) for supporting and moving the cutting wire (1), wherein said at least one cutting wire (1) is a cutting wire according to the preceding claim.

43. A manufacturing method of a cutting wire for cutting into slabs blocks of stone material according to claim 41, the method comprising the following steps:

1) providing a flexible support structure (2);

2) providing a plurality of diamond beads (5) each comprising a tubular support (4) and a diamond outer member (3) coupled externally to said tubular support (4) and designed to interact with the stone material to cut it;

3) Inserting of said diamond beads (5) on said flexible support structure (2);

4) manufacturing of a plurality of spacer elements (9) in polymeric material interposed between the flexible support structure (2) and said diamond beads (5) to mutually block them; wherein each of said tubular supports (4) is the tubular support according to any one of the claims 38 to 40.