The diamond wire cutter (DWC) is a crucial tool for subsea pipeline repairs. However, in the event of a saw wire failure, replacing and connecting the diamond wire on the seabed is unfeasible due to constraints in underwater construction conditions. To extend the service life of diamond wires, this study examines the micro-wear morphology of diamond beads through low-temperature grinding experiments. The wear mechanisms of diamond grains are revealed, and the wear process of the diamond bead is deduced. Utilizing wear experimental data and a BP neural network, the wear rate prediction model of electroplated diamond wire during subsea pipe continuously cutting is constructed. Additionally, the effects of cutting parameters, wire lengths, and pipe diameters on bead wear rates are analyzed. Findings indicate that the wear behavior of diamond grains includes fracture, thermal wear, and grain detachment. Compared to the (111) crystal surface, the (100) crystal surface exhibits superior wear resistance. During electroplated diamond wire continuously cutting subsea pipes, the saw wire achieves optimal service life at a cutting speed of 22 m/s and a feed speed of 1.1 mm/min. This study offers theoretical guidance for diamond wire underwater construction programs.
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