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ABSTRACT
The dominant method to cut brittle materials is using fixed-abrasive wire saw slicing. This paper investigates the mechanism of pneumatic conveying diamond grains in the process of manufacturing diamond wire saws. Based on the theories of gas–solid two-phase flow, a mathematical model is developed for the process of diamond grains embedding into the metal-covered wire with resin. The model is divided into five stages for insights into the action of diamond grains. Then the embedding rate is calculated. From the experiments, we can compare the theoretical analysis and practical results of the embedding depth of diamond grains under different pressures in a three-dimensional microscopy experimental setup. With the present mathematical model, it is feasible to produce diamond wires by the method of pneumatic conveying diamond grains with the help of this study.