In Chinese quarries, the common method for quarrying involves using a circular saw for side cuts and a diamond wire for bottom cuts. Efficient use of the diamond wire saw is crucial for cost control, especially during the bottom cutting process. This article explores techniques to maintain high efficiency and extend the service life of diamond wire saws.
Maximizing Efficiency in Bottom Cutting
Optimal Design for Wire Saw Line
To maintain high efficiency in quarry cutting, it's essential to minimize the contact length between the diamond wire and the stone. Reducing this contact length decreases frictional force, thereby improving the equipment's energy consumption utilization rate. Additionally, designing the cutting angle of the wire saw as large as possible helps to minimize the bending range of the wire, which enhances the longevity of the wire saw.
Challenges and Solutions Near Completion
Problem: Reduced Bending Range
As the cutting nears completion, with about 5 cm remaining, the bending range of the wire saw decreases. This reduction makes it difficult for the diamond wire to rotate properly, leading to issues such as one-side polishing and taper formation at the front of the diamond beads. Continuing with the same process or reducing the linear speed can exacerbate these problems, significantly affecting the wire's lifespan.
Solution: Techniques for Improved Longevity
To improve the service life of the diamond wire and reduce costs, two primary strategies can be employed:
1. Replacing the Old Rope:
When the cutting is nearly complete, replacing the old rope minimizes damage to the new diamond wire. This ensures that the new wire can be utilized to its maximum potential, reducing overall costs.
2. High Speed and Low Current Operation:
When finishing the cutting, using a high linear speed (generally more than 30 m/s) and low current (close to the no-load current) can extend the wire's service life. This technique can increase the overall lifespan of the diamond wire by more than 10% to 15%, offering significant cost savings over time.
Practical Application Tips
1. Monitor Wire Wear:
Regularly check the condition of the diamond wire, especially near the end of the cutting process, to decide the optimal time for replacing or adjusting the wire.
2. Adjust Cutting Parameters:
Fine-tune the linear speed and current based on the specific conditions of the cut. This proactive adjustment helps prevent excessive wear and ensures a smoother finish.
3. Use Guide Wheels:
Implement guide wheels to reduce the contact area between the wire and the stone, which helps in maintaining a consistent cutting angle and reducing friction.
4. Cooling and Lubrication:
Ensure adequate water supply to cool the wire, reducing heat generation and prolonging the wire's lifespan. Proper cooling also helps in maintaining the wire's cutting efficiency.
Efficient use of diamond wire saws in quarrying, particularly for bottom cutting, involves strategic planning and execution. By optimizing the wire saw line design, adjusting cutting parameters, and employing techniques like rope replacement and high-speed, low-current operation, you can significantly enhance the wire's service life and reduce costs. Implementing these strategies ensures efficient, cost-effective quarrying operations.
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References:
- How to Keep Sharpness of Multiwire for Optimal Cutting?
- How Circular Saws and Diamond Wire Saws Work Together
- Fili Product Information
- what is diamond wire saw?