Energy consumption and wear rate of diamond beads during operation of a diamond wire saw
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2023-12-12 |
| Journal | E-Zbornik elektroniÄki zbornik radova GraÄevinskog fakulteta |
| Authors | Tomislav Korman, Trpimir KujundĆŸiÄ, Ć ime VrandeÄiÄ |
| Institutions | University of Zagreb |
| Analysis | Full AI Review Included |
Executive Summary
Section titled âExecutive SummaryâThis review paper analyzes the critical factors influencing the efficiency, energy consumption, and wear rate of diamond beads during the operation of diamond wire saws (DWS) in dimension stone quarrying.
- Efficiency Metrics: Sawing efficiency (m2/h) and specific bead wear (”m/m2) are the primary indicators of DWS performance, directly depending on resistances encountered during cutting.
- Rock Property Influence: Uniaxial Compressive Strength (UCS) is the decisive uncontrolled parameter; increasing UCS significantly decreases cutting speed and increases bead wear. Hardness, abrasiveness, and texture coefficient also show significant correlation.
- Operational Optimization: Controlled parameters, including feed force (traction), cutting angle, and machine position, must be optimized based on rock type and cut geometry to maximize efficiency.
- Geometric Gains: Utilizing a lateral saw position for horizontal cuts yielded up to 14.6% higher average sawing efficiency compared to a central position. Optimal saw distance for vertical cuts is critical and scales with bench height (e.g., 3 m distance for a 7 m bench).
- Design Impact: Increasing the drive wheel diameter improves cutting efficiency and reduces dynamic stresses on the wire by minimizing acceleration fluctuations.
- Wear Management: Bead wear is minimized by selecting the optimal number of beads per meter (e.g., 31 beads/m for travertine) and avoiding excessive traction force, which causes detrimental conical wear, particularly in granite.
Technical Specifications
Section titled âTechnical Specificationsâ| Parameter | Value | Unit | Context |
|---|---|---|---|
| Typical Drive Motor Power Range | 30 to 75 | kW | Standard DWS machines. |
| Standard Steel Rope Diameter | ~5 | mm | Inner diameter of diamond beads is typically 5 mm. |
| Limestone Bead Outer Diameter | 10 | mm | Sintered cylindrical type. |
| Limestone Bead Length | 8.5 | mm | Total length. |
| Diamond Grit Size (Limestone) | 40/50 | mesh | Synthetic SDA type. |
| Diamond Concentration (Limestone) | 35 | % | Standard concentration. |
| Travertine/Marble Sawing Efficiency | 5 to 12 | m2/h | Efficiency range in softer rocks. |
| Granite Sawing Efficiency | 2 to 5 | m2/h | Efficiency range in harder rocks. |
| Efficiency Gain (Lateral Cut) | 14.6 | % | Improvement over central position for horizontal cuts. |
| Optimal Beads per Meter (Travertine) | 31 | beads/m | Maximizes efficiency during the middle third of wire lifetime. |
| Optimal Saw Distance (7m Bench) | 3 | m | Distance from saw to working face for vertical cuts. |
| Optimal Saw Distance (12m Bench) | 4.5 | m | Distance from saw to working face for vertical cuts. |
| Feed Motor Current Range (Tested) | 45 to 65 | amperes | Used to adjust traction force during testing. |
| Specific Wear (UW) Formula | (d0 - d1) / A | ”m/m2 | Change in bead diameter (”m) divided by sawn area (m2). |
Key Methodologies
Section titled âKey Methodologiesâ- Parameter Classification: Parameters affecting DWS efficiency were systematically divided into Uncontrolled (rock properties: strength, hardness, abrasiveness) and Controlled (design values: motor power, bead density; operating values: feed force, cutting angle).
- Specific Energy Modeling: Laboratory tests were conducted on various igneous rocks (diorite, granite, syenite) to correlate geological properties (density, p-wave velocity) with Specific Energy (SE) consumption, resulting in a multiple regression model for SE prediction (85.8% accuracy).
- Efficiency Testing (Geometry): Field studies analyzed the influence of cut geometry, comparing central versus lateral saw positions for horizontal cuts and varying the distance between the saw and the bench face (1.5 m to 5.5 m) for vertical cuts on benches up to 12 m high.
- Traction Force Optimization: Tests were performed on travertine blocks (50 m2 to 100 m2 area) by adjusting the feed motor current (45 A to 65 A) to determine the optimal wire tension required for maximum sawing efficiency based on cut surface area.
- Bead Wear Measurement: Wear was quantified using the Specific Wear (UW) metric, calculated by measuring the change in bead diameter (d0 - d1) using micrometers or image processing, normalized against the total sawn area (A).
- Design Optimization Testing: The influence of design variables, such as the number of beads per meter (tested up to 32 beads/m) and the drive wheel diameter (tested up to 95 cm), was analyzed against cutting efficiency and dynamic stress reduction.
Commercial Applications
Section titled âCommercial Applicationsâ- Dimension Stone Extraction: Primary application for high-efficiency quarrying of large architectural blocks (marble, granite, limestone, travertine).
- Quarry Planning and Operations: Utilizing optimal geometric guidelines (lateral positioning, specific saw-to-face distance) to maximize output (m2/h) and minimize operational downtime.
- Consumable Tool Design: Informing the design and material selection of diamond beads (grit size, concentration, matrix composition) to match specific rock abrasiveness and strength characteristics, thereby extending wire service life.
- Machine Control Systems: Developing automated DWS systems that dynamically regulate operating parameters (linear speed, feed force/traction) based on real-time resistance measurements to prevent excessive bead wear (e.g., conical wear) and maintain optimal efficiency.
- Cost Engineering: Providing data necessary for accurate cost modeling, allowing quarry operators to select the optimal wire assembly (beads/m) and operational settings to reduce the cost per square meter cut.
View Original Abstract
Diamond wire saws are indispensable machines for the extraction and processing of dimension stones. The cutting speed, energy consumption and wear rate of the diamond beads are the most important factors in assessing the efficiency of a diamond wire saw. The parameters that influence the efficiency of the diamond wire saw can be divided into controlled and uncontrolled parameters. Uncontrolled parameters cannot be influenced directly and are related to the rock types and their properties such as strength, hardness and abrasiveness. Controlled parameters are related to the operating parameters and technical characteristics of the machine. The energy consumption and the service life of the diamond wire are directly related to the characteristics of the machine and the design of the diamond wire, such as the power of the drive motor, the diameter of the drive wheel, diamond grit size and the diameter of the wire. The operating parameters of the diamond wire saw, such as cutting speed, cutting surface, cutting angle, wire tension and cooling water flow, also have a significant influence. Based on previous studies, the influence of the above parameters on the consumption of energy and wear rate of diamond beads in the operation of a diamond wire saw was analyzed.