Design and Development of a Numerical Model and Study on Kinematic Analysis of a Circular Diamond Saw Blade for Ceramics
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2021-12-13 |
| Journal | International Journal for Research in Applied Science and Engineering Technology |
| Authors | N. Balasubramanyam |
| Analysis | Full AI Review Included |
Executive Summary
Section titled âExecutive SummaryâThis study presents the design, numerical modeling, and kinematic analysis of a 400 mm segmented circular diamond saw blade optimized for cutting ceramics and hard stone materials.
- Design Optimization: A novel radial slot profile (Conical slot) was introduced and compared against the standard Circular slot design across blades with 8, 12, 16, and 20 segments to mitigate noise, vibration, and thermal expansion issues.
- FEA Methodology: Finite Element Analysis (FEA) using ANSYS 5.4 was employed for coupled thermal-structural analysis, focusing on deformation, stress distribution, and natural frequency calculation.
- Performance Metrics: The Conical slot design demonstrated superior structural performance, yielding lower total deformation compared to the Circular slot across all segment counts (e.g., 0.208 mm vs. 0.213 mm for 20 segments).
- Kinematic Forces: Kinematic analysis confirmed that both Normal Force (Fn) and Tangential Force (Ft) increase significantly with increasing cutting speed and depth of cut. The Normal Force (Fn) was consistently less than the Tangential Force (Ft).
- Wear Resistance: Segmented diamond saw blades exhibited significantly better wear performance (average wear 0.732) and lower material loss (6.29 g) compared to continuous diamond saw blades (average wear 1.168; loss 10.93 g).
- Modeling Achievement: A new cutting power model and mathematical modeling for chip thickness were successfully presented and validated.
Technical Specifications
Section titled âTechnical Specificationsâ| Parameter | Value | Unit | Context |
|---|---|---|---|
| Blade Diameter | 400 | mm | Design specification |
| Segment Count (Tested) | 8, 12, 16, 20 | N/A | Variable design parameter |
| Blade Core Youngâs Modulus | 210 | GPa | Material property (High-strength steel) |
| Segment Youngâs Modulus | 120 | GPa | Material property (Diamond composite) |
| Blade Core Density | 7600 | kg/m3 | Material property |
| Segment Density | 8500 | kg/m3 | Material property |
| Max Total Deformation (20 Segments, Conical Slot) | 0.208 | mm | FEA result (Lowest deformation achieved) |
| Max Von Mises Stress (8 Segments, Conical Slot) | 326.88 | N/A | FEA result (Highest stress recorded) |
| Circumferential Speed (Kinematic Baseline) | 30 | m/s | Standard operating condition |
| Max Tangential Force (Ft) | 521 | N | At 0.45 m/min cutting speed, 25 mm depth |
| Max Normal Force (Fn) | 193 | N | At 0.45 m/min cutting speed, 25 mm depth |
| Segmented Blade Average Wear | 0.732 | N/A | Superior wear resistance |
| Continuous Blade Average Wear | 1.168 | N/A | Baseline comparison |
| Lowest Natural Frequency (400 mm blade) | 40.17 | Hz | 20 segments, Circular slot with annular slot |
Key Methodologies
Section titled âKey MethodologiesâThe study employed a combination of CAD modeling and advanced Finite Element Analysis (FEA) to simulate and validate the saw blade performance.
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Design and Modeling (SolidWorks):
- Segmented diamond saw blades (400 mm diameter) were designed with varying segment counts (8, 12, 16, 20).
- Two primary radial slot profilesâCircular Slot (CR) and a novel Conical Slot (CON)âwere modeled to manage vibration, noise, and thermal expansion.
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Finite Element Analysis (ANSYS 5.4):
- The model was treated as two-dimensional (2D) and divided into two parts: the high-strength steel body (core) and the diamond composite segments.
- Meshing: Shell elements (eight-nodded isoperimetric finite elements) were used, totaling 14004 elements and 43146 nodes. Smaller elements were concentrated in the tooth root regions for precise stress outcome.
- Analysis Type: Coupled thermal-structural analysis was performed to simulate real-world operating conditions, determining stress distribution, deformation, and temperature conveyance.
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Kinematic Analysis:
- The experiment validated performance based on key operational characteristics: normal force (Fn), tangential force (Ft), cutting speed (Vf), cut depth (d), and peripheral velocity.
- Forces were measured across cutting speeds ranging from 0.25 m/min to 0.45 m/min and cut depths from 15 mm to 25 mm, using a circumferential speed of 30 m/s as a baseline.
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Vibration Testing:
- Natural frequencies were computed for various segment/slot configurations to assess dynamic stability and potential for resonance during high-speed operation.
Commercial Applications
Section titled âCommercial ApplicationsâThe optimized design and modeling techniques are directly applicable to industries requiring high-efficiency, low-vibration cutting of hard, abrasive materials.
- Construction and Infrastructure: Used in diamond asphalt and concrete cutting machines for quick, clean section removal and replacement (e.g., bridge and highway surfaces).
- Stone Processing and Quarrying: Essential for sawing natural rock sections, including hard rocks like granite, marble, and other decorative/constructional materials.
- Ceramics Manufacturing: High-precision cutting of ceramic tiles and advanced ceramic components, where thermal stability and minimal deformation are critical.
- Tool Manufacturing: The numerical modeling approach provides a cost-effective method for designing and optimizing super abrasive diamond tools, reducing the need for extensive physical prototyping.
View Original Abstract
Abstract: Diamond tools are currently being used by an increasing number of architects, miners and construction engineers because they are faster and easier to use than older, more traditional instruments like sledge hammers and pneumatic and hydraulic jacks. Bridge and highway surfaces are cut with diamond asphalt and concrete cutting machines to provide for quick, clean, and easy section removal and replacement. The entire cost is reduced since diamond tools take less time and manpower The experiment is carried out to validate the performance of diamond saw blades by taking into consideration characteristics such as normal force, tangential force, cutting speed, cut depth, and peripheral velocity. In present exploration work we are introductory phase of plan conclusion of a jewel device cutting edge with various segmental like 8,12,16,20 corn meal by utilizing Solid works programming we are planning the apparatus cutting edge after that we are imported in Ansys Software for Analysis reason. Computing the necessary qualities for examination and estimations of earthenware tiles likewise are some other stone molecule. Another power model of cutting is presented and inferred numerical demonstrating for chip thickness. Identical chip thickness to coarseness space proportion is gotten from the new power model another outspread opening like profile is presented. Fragmented sort jewel saw sharp edge with the measurement of 400 mm and different portion, for example, 8, 12, 16 and 20 are planned in Solid works effectively. An examination study between existing roundabout outspread space and cone like opening is done to decide deformity, stress dispersion, vibration and temperature conveyance.