ANALYSIS OF THE WEAR MECHANISM OF DIAMOND GRAINS AT DIFFERENT CUTTING SPEEDS
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2025-01-01 |
| Journal | Naukovyi visnyk Donetskoho natsionalnoho tekhnichnoho universytetu |
| Authors | Andrii Sydorenko, Serhii Mykytenko |
| Analysis | Full AI Review Included |
Executive Summary
Section titled âExecutive SummaryâThis study investigated the wear mechanism of diamond grains in saw blades cutting Kapustinsky granite to define optimal operational parameters for improved efficiency and tool lifespan.
- Optimal Operating Regime: The most balanced performance (productivity vs. wear) was achieved at a cutting speed (Vc) of 30-35 m/s combined with a feed rate (f) of 1.2 mm/rev.
- Mechanism at Optimal Speed: This range ensures stable self-sharpening (grain renewal), where worn grains are effectively released from the bond matrix, exposing new, sharp crystals, maintaining high cutting ability.
- Impact of High Speed (Vc > 35 m/s): High speeds lead to intense mechanical and thermal loading, causing rapid destruction. The proportion of cracked grains exceeds 30%, and pulled-out grains reach 15-20%, significantly shortening tool life.
- Impact of Low Speed (Vc < 25 m/s): Low speeds result in insufficient kinetic energy for effective self-sharpening. Grains become glazed or smoothed (up to 40% smoothed grains), increasing friction, reducing productivity, and raising energy consumption.
- Economic Benefits: Implementing the optimal regime is projected to reduce tool replacement costs by 15% and extend the operational resource (lifespan) of the diamond disks by 20-25%.
- Methodology: Wear was quantified by classifying diamond grain morphology (unworn, glazed, cracked, pulled out) using electron microscopy (200x magnification) after controlled cutting stages.
Technical Specifications
Section titled âTechnical SpecificationsâThe following table summarizes the key experimental parameters and performance metrics derived from the study on cutting Kapustinsky granite.
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Optimal Cutting Speed (Vc) | 30-35 | m/s | Range for balanced wear and renewal |
| Optimal Feed Rate (f) | 1.2 | mm/rev | Recommended feed rate |
| High Feed Rate Tested | 1.6 | mm/rev | Leads to increased mechanical load and wear |
| Low Speed Range | 20-25 | m/s | Insufficient self-sharpening |
| High Speed Range | 35-45 | m/s | Accelerated grain destruction |
| Diamond Disk Diameter | 600 | mm | Edging machine specification |
| Drive Motor Power | 7.5 | kW | Edging machine specification |
| Test Material | Kapustinsky Granite | N/A | High hardness, complex microstructure |
| Test Slab Thickness | 20 | mm | Dimension of granite processed |
| Microscopy Magnification | 200 | times | Used for grain morphology analysis |
| Projected Tool Cost Reduction | 15 | % | Practical economic benefit |
| Projected Disk Lifespan Increase | 20-25 | % | Practical economic benefit |
| Cracked Grains (Vc > 40 m/s) | >30 | % | Indicates intense structural failure |
| Pulled-out Grains (Vc = 45 m/s) | Up to 20 | % | Indicates bond failure |
Key Methodologies
Section titled âKey MethodologiesâThe research employed a controlled experimental setup and micro-geometric analysis to evaluate diamond grain wear:
- Equipment and Material: A specialized edging machine with a 7.5 kW motor and a 600 mm diamond saw blade (Wanlong segments) was used to cut 20 mm thick slabs of high-hardness Kapustinsky granite.
- Variable Testing: Experiments systematically varied the cutting speed (Vc) from 20 m/s to 45 m/s, testing two primary feed rates (f): 1.2 mm/rev and 1.6 mm/rev.
- Segment Sampling: After each 4-hour cutting stage, three diamond segments were removed from the disk for post-processing analysis.
- Microscopic Analysis: Wear was assessed using a LAICA electron microscope at 200x magnification to analyze the morphology of at least 30 reference grains per segment.
- Wear Classification: Diamond grains were categorized into four states to quantify the wear mechanism:
- Unworn: Grains retaining their original sharp cutting edges.
- Glazed/Smoothed: Grains that lost sharp edges due to friction (micro-erosion).
- Cracked: Grains exhibiting micro-fractures due to cyclic or impact loading.
- Pulled Out: Grains completely separated from the metal bond matrix.
- Performance Metric: Tool productivity and efficiency were determined by analyzing the ratio of damaged grains (smoothed, cracked, pulled out) relative to the unworn grains across the tested speed and feed regimes.
Commercial Applications
Section titled âCommercial ApplicationsâThe findings of this research provide direct, actionable data for optimizing operations in the hard material processing sector.
- Dimension Stone Processing: Direct application in optimizing cutting parameters for high-hardness granites (like Kapustinsky granite) and other abrasive natural stones, ensuring maximum yield and surface quality.
- Diamond Tool Manufacturing: The data on grain destruction rates at high speeds informs the development of improved bond matrices (e.g., Cu-Co-Ni-Zn-Sn alloys) that offer better thermal stability and mechanical retention for high-speed applications.
- Operational Cost Reduction: Implementation of the 30-35 m/s regime allows stone processing facilities to achieve significant savings (15% reduction in tool costs) and reduce downtime associated with frequent tool changes.
- Process Automation: The defined optimal speed range can be integrated into CNC (Computer Numerical Control) systems for automated cutting machines, ensuring stable self-sharpening and consistent cutting efficiency.
- Energy Efficiency: By avoiding low cutting speeds (which increase friction and cutting forces) and excessively high speeds (which cause rapid segment failure), the optimized regime contributes to lower specific energy consumption during granite processing.
View Original Abstract
The aim of this study is to investigate the wear mechanism of diamond grains at different cutting speeds and determine the optimal conditions to improve the efficiency of granite processing using diamond saw blades. The study considers both cutting speed parameters and feed rate to establish optimal operating conditions that achieve high productivity with minimal tool wear and an extended tool lifespan. The research was conducted using a specialized edging machine equipped with a 600 mm diamond saw blade. The object of study was Kapustinsky granite, characterized by high hardness and a complex microstructure. During the experiment, the wear of diamond grains was measured using electron microscopy after each cutting stage. Two main feed rate options were used: 1,2 mm/rev and 1,6 mm/rev. The cutting speed varied between 20 and 45 m/s. The results of the study showed that the optimal cutting speed for achieving balanced cutting efficiency and minimal diamond grain wear is 30-35 m/s. At these speeds, effective grain renewal is ensured, maintaining the cutting ability of the tool at a sufficient level. Higher speeds (above 35 m/s) lead to intense destruction of diamond grains, an increase in the proportion of cracked and worn grains, and a decrease in productivity and tool lifespan. Additionally, speeds below 25 m/s result in insufficient grain renewal, which also reduces cutting efficiency. Based on the results, the optimal cutting speed for working with Kapustinsky granite was determined to be 30-35 m/s at a feed rate of 1,2 mm/rev. Using these conditions ensures stable grain renewal, reduces tool wear, and improves processing efficiency. Practical recommendations derived from this study allow for a 15 % reduction in tool replacement costs, improve cutting process efficiency, and extend the lifespan of diamond saw blades by 20-25 %. This will help reduce overall production costs and improve the competitiveness of the stone processing industry. The scientific novelty of this study lies in analyzing the impact of different cutting speeds on the wear pattern of diamond grains and determining optimal operating conditions to reduce energy consumption and improve the productivity of hard material processing. The recommended regimes can be applied to enhance technological processes in the stone processing industry, which is an important factor for improving economic efficiency and the quality of natural stone processing. Keywords: diamond grains, cutting speed, wear, cutting efficiency, granite processing, diamond tools, optimal conditions, stone processing industry.