Effect Of Sawing Rate On Force And Energy Requirements In The Circular Sawing Of Granites

In the stone processing industry, sawing rate and sawblade life are the main parameters economically affecting the process. However, the relative importance ranking of these parameters may vary depending on the needs and priorities of the plant. In this study, utilizing a fully instrumented circular side-cutting machine, the effect of sawing rate on force and energy requirements of two selected granite types were investigated. It was concluded that, when it is intended to achieve higher sawing rates, employing a higher feed velocity and a shallower cutting depth improves the efficiency of the process in terms of cutting forces, power and specific energy. However, the magnitude of this improvement varies according to the mineralogical properties of the tested rock.

Effect Of Sawing Rate On Force And Energy Requirements In The Circular Sawing Of Granites

In the stone processing industry, sawing rate and sawblade life are the main parameters economically affecting the process. However, the relative importance ranking of these parameters may vary depending on the needs and priorities of the plant. In this study, utilizing a fully instrumented circular side-cutting machine, the effect of sawing rate on force and energy requirements of two selected granite types were investigated. It was concluded that, when it is intended to achieve higher sawing rates, employing a higher feed velocity and a shallower cutting depth improves the efficiency of the process in terms of cutting forces, power and specific energy. However, the magnitude of this improvement varies according to the mineralogical properties of the tested rock.

___

  • [1] J. Konstanty, “Theoretical analysis of stone sawing with diamonds”, Journal of Materials Processing Technology, Vol.123, pp.146-154, 2002.
  • [2] B. Unver, “A statistical method for practical assessment of sawability of rocks”, Proc. of ISRM Int. Symp.Eurock 96’, 1996, Barla (Edt.), Rotterdam, Balkema, pp.59-65.
  • [3] H.K. Tonshoff, J. Asche, “Wear of metal-bond diamond tools in the machining of stone”, Industrial Diamond Review, Vol. 1, pp.7-13, 1997.
  • [4] W. Ertingshausen, “Wear processes in sawing hard stone”, International Diamond Review, Vol.5, pp.254-258, 1985.
  • [5] S.Y. Luo, “Investigation of the worn surfaces of diamond sawblades in sawing granite”, Journal of Materials Processing Technology, Vol.70, pp.1-8, 1997.
  • [6] X.P. Xu, Y. Li, W.Y. Zeng, L.B. Li, “Quantitative analysis of the loads acting on the abrasive grits in the diamond sawing of granites”, Journal of Materials Processing Technology, Vol.129, pp.50-55, 2002.
  • [7] A.S. Eyuboglu, Y. Ozcelik, S. Kulaksiz, I.C. Engin, “Statistical and microscopic investigation of disc segment wear related to sawing Ankara andesites”, International Journal of Rock Mechanics & Mining Sciences, Vol.40, pp.405-414, 2003.
  • [8] A. Ersoy, S. Buyuksagis, U. Atici, “Wear characteristics of circular diamond saws in the cutting of different hard and abrasive rocks”, Wear, Vol.258, pp.1422-1436, 2005.
  • [9] A.D. Ilio, A. Togna, “A theoretical wear model for diamond tools in stone cutting”, International Journal of Machine Tools and Manufacture, Vol. 43, pp.1171-1177, 2003.
  • [10] H.K. Tonshoff, H. Hillman-Apman, J. Asche, “Diamond tools in stone and civil engineering industry: cutting principles, wear and applications”, Diamond and Related Materials, Vol.11, pp.736-741, 2002.
  • [11] X. Xu, Y. Li, Y. Yu, “Force ratio in the circular sawing of granites with a diamond segmented blade”, Journal of Materials Processing Technology, Vol.139, pp.281-285, 2003.
  • [12] X. Xu, Y. Li, S. Malkin, “Forces and energy in circular sawing and grinding of granite”, Journal of Manufacturing Science and Engineering, Vol.123, pp.13-22, 2001.
  • [13] A.G. Mamalis, R. Schulze, H.K. Tönshoff, “The slotting of blocks of hard rock with a diamond segmented circular sawblade”, Industrial Diamond Review, Vol.39, pp. 356-365, 1979.
  • [14] M. Jennings, D. Wright, “Guidelines for sawing stone”, Industrial Diamond Review, Vol.2, pp.70-75, 1989.
  • [15] C.Y. Wang, X. Wei, Z.L. Tang, Z.C. Pan, “The role of coolant in granite sawing”, Industrial Diamond Review, Vol.4, pp.156-160, 1995.
  • [16] X. Wei, C.Y. Wang, Z-H. Zhou, “Study on the fuzzy ranking of granite sawability”, Journal of Materials Processing Technology, Vol.139, pp.277-280, 2003.
  • [17] P. Hausberger, “Stone Machineability”, Industrial Diamond Review, Vol.5, pp.258-261, 1990.
  • [18] H.K. Tönshoff, G. Warnecke, “Research on stone sawing”, Advances in Ultrahard Materials Application Technology, Vol. 1, pp.36-49, 1982.
  • [19] N.S. Delgado, A. Rey-Rodrigez, L.M. Suarez del Rio, I.D. Sarria, L. Calleja, V.G. Ruiz de Argandona, “The influence of rock microhardness on the sawability of Pink Porrino granite (Spain)”, International Journal of Rock Mechanics & Mining Sciences, Vol. 42, pp.161- 162, 2005.
  • [20] S. Lan, P. Jinsheng, L. Changjian, “A new approach to improve the performance of diamond sawblades”, Materials Letters, Vol.57, pp.1010-1014, 2002.
  • [21] I.S. Buyuksagis, “Effect of cutting mode on the sawability of granites using segmented circular diamond blades”, Journal of Materials Processing Technology, Vol.183, pp.399- 406, 2007.
  • [22] J. Asche, “Deep grinding- a new dimension in cutting granite”, Industrial Diamond Review. Vol.2, pp.110-122, 1999.
  • [23] S.M. Çınar, “Optimization of Electric Energy Consumption in Marble Cutting Machines”, Afyon Kocatepe Üniversitesi Fen Bilimleri Enstitüsü, Yüksek Lisans Tezi (In Turkish), 2007.
  • [24] Turkish Standard TS EN 1926, Natural stone test methods – Determination of compressive strength, April 2000.
  • [25] Turkish Standard TS EN 13161, Natural stone test methods – Determination of flexural strength, February 2003.
  • [26] Y. Li, H.Huang, J.Y. Shen, X.P. Xu, Y.S. Gao, “Cost-effective machining of granite by reducing tribological interactions”, Journal of Materials Processing Technology, Vol.129, pp.389-394, 2002.
  • [27] W. Polini, S. Turchetta, “Force and specific energy in stone cutting by diamond mill”, International Journal of Machine Tools & Manufacture, Vol.44, pp.1189-1196, 2004.
  • [28] B. Brook, “Principles of diamond tool technology for sawing rock”, International Journal of Rock Mechanics and Mining Sciences, Vol.39, pp. 41-58, 2002.
  • [29] X. XU, “Friction studies on the process in circular sawing of granites”, Tribology Letters, Vol.7, pp.221-227, 1999.
  • [30] W. Polini, S. Turchetta, “Monitoring of diamond disk wear in stone cutting by means of force or acceleration sensors”, International Journal of Advanced Manufacturing Technology. Vol.35, pp.454-467, 2007.
  • [31] Y. Ozcelik, S. Kulaksiz, A.S. Eyuboglu, “Investigation of the effect of rock parameters on the specific energy in cutting process of Ankara-Cubuk Andesites with disc cutter”, Proc. of the ISRM Regional Symposium Eurock, 2001, pp. 597-602.
  • [32] I.S. Buyuksagis, R.M. Goktan, “Investigation of marble machining performance using an instrumented block-cutter”, Journal of Materials Processing Technology, Vol.169, pp. 258- 262, 2005.
  • [33] V.B. Cassapi, “Factors influencing the sawability of stones”, Ph.D. Thesis, University of Nottingham, England, 1987.