Experimental Analysis of Abrasive Diamond Tool Wear and their Cutting Force in Stone Machining Process
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2021-07-31 |
| Journal | International Journal for Research in Applied Science and Engineering Technology |
| Authors | N. Balasubramanyam |
| Analysis | Full AI Review Included |
Executive Summary
Section titled âExecutive Summaryâ- Objective: Experimental comparison of abrasive wear rates (weight loss and segment height loss) for two commercially available diamond cutting discs (Disc-I and Disc-II) used in granite machining.
- Methodology: Both discs were tested under identical, standard industrial cutting conditions (constant feed rate, speed, and depth of cut) over a total operational time of 100 hours.
- Key Finding (Wear Profile): Both diamond discs exhibited a strong linear dependency between material loss (weight/height) and cutting time, indicating uniform dispersion of diamond particles within the segment matrix.
- Performance Comparison: Disc-II demonstrated superior wear resistance, losing 7.87% of its weight and 48% of its segment height.
- Performance Comparison (Cont.): Disc-I showed a higher wear rate, losing 9.59% of its weight and 55% of its segment height over the same 100-hour period.
- Conclusion: The results provide quantitative data for a cost-benefit analysis, confirming that the disc from the manufacturer corresponding to Disc-I has a higher overall wear rate under the tested conditions.
Technical Specifications
Section titled âTechnical SpecificationsâThe following parameters were maintained during the cutting operation on granite, and the resulting wear losses were measured after 100 hours.
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Total Monitoring Time | 100 | hours | Duration of experiment |
| Speed Feed (Vf) | 3.2 | â | Cutting condition |
| Depth Cut | 8 | â | Cutting condition |
| Spindle Speed (n) | 1450 | RPM | Rotational speed |
| Angular Speed (Ď) | 151,844 | â | Calculated value (2 * Ď * n) |
| Wheel Diameter | 500 | mm | Both discs |
| Segment Width | 3.8 | â | Both discs |
| Number of Teeth | 60 | â | Both discs |
| Disc-I Total Weight Loss | 0.463 | kg | After 100 hours |
| Disc-II Total Weight Loss | 0.379 | kg | After 100 hours |
| Disc-I Weight Loss (Percent) | 9.59 | % | Relative loss of initial mass |
| Disc-II Weight Loss (Percent) | 7.87 | % | Relative loss of initial mass |
| Disc-I Height Loss | 10.87 | mm | After 100 hours |
| Disc-II Height Loss | 9.456 | mm | After 100 hours |
| Disc-I Height Loss (Percent) | 55 | % | Relative loss of initial height |
| Disc-II Height Loss (Percent) | 48 | % | Relative loss of initial height |
Key Methodologies
Section titled âKey MethodologiesâThe experimental analysis focused on monitoring the abrasive wear of the diamond segments during the cutting of granite using a formatting saw.
- Tool Preparation: Two diamond cutting discs (Disc-I and Disc-II) of 500 mm diameter, 60 teeth, and 3.8 mm segment width were selected.
- Process Setup: The discs were operated under constant, standard industrial cutting conditions: 1450 RPM spindle speed, 3.2 feed speed, and 8 depth cut.
- Measurement Cycle: The machine saw was periodically halted, and the operational time was recorded. The disc was removed from the spindle for measurement.
- Weight Measurement: The disc was thoroughly dried to eliminate weight skew from clinging water drops before measuring the total weight loss (kg) as a function of time.
- Segment Height Measurement: Segment height was measured using a digital caliper. To account for slight variations due to the solder amount at the tooth root, measurements were taken on 5 to 10 teeth around the circumference, and an average value was determined.
- Wear Mechanism Focus: The study primarily addressed abrasive wear, defined as the mechanical loss of the cutting segment due to the relative movement of the blade against the granite workpiece.
- Tool Fabrication Context: The paper provided background on diamond tool manufacturing, including segment attachment methods:
- Soldering: Uses solder melting at 600 to 800° C, typically water-cooled for large diameter saws.
- Laser Welding: Melts a thin layer of steel core and segment, embedding the segment without requiring water cooling.
- Sintering: High-pressure pressing used to create a junction between the segment mixture and microscopic teeth cut into the steel core.
Commercial Applications
Section titled âCommercial Applicationsâ- Stone Quarrying and Processing: Direct application in optimizing tool selection for high-volume cutting of hard natural stones, particularly granite, slabs, and tiles, using industrial formatting and block saws.
- Abrasive Tool Procurement: Provides quantitative data (linear wear rate guidelines) necessary for purchasing managers and engineers to select the most cost-effective and durable diamond wheels (e.g., Disc-II showed 7% better weight retention than Disc-I).
- Tool Design and Metallurgy: The findings on linear wear dependency inform diamond tool manufacturers regarding the uniformity of diamond particle distribution and the effectiveness of the metallic binder matrix.
- Process Control Engineering: Used to establish optimal operating parameters (feed rate, circumferential speed, cut depth) to ensure system stability, minimize vibrations, and prevent rapid wear caused by excessive sludge thickening in the cut.
- Hard Material Machining: The principles of abrasive wear analysis are transferable to other sectors requiring the cutting of extremely hard materials, such as concrete, asphalt, and ceramics.
View Original Abstract
Stone machining with a diamond tool is a common procedure for producing both standard items and design shapes, such as tiles, slabs and so on. During the entire deep sawing process of a granite work piece with finite length cutting procedure in stone processing, force components acted on the saw-blade. The work is split into two parts: theoretical and practical. The theoretical section discusses the features of diamond blades, cutting process methodology, and stone mining and processing methods. The practical portion of the project focuses on the wear of diamond blades when cutting stone, notably granite. The overall weight of the cutting blade and the loss of tooth height as a function of time are used to determine blade wear for two cutting blades from different manufacturers. There is a linear relationship between the two measured values. The findings serve as the foundation for a cost-benefit analysis of both diamond wheels.