Cutting efficiency is crucial for most factories. High efficiency translates to lower time and electricity costs and increased productivity. Many factories encounter a common issue with new diamond wires: the initial cutting efficiency is high but gradually decreases during use. Based on our experience, there are measures to maintain cutting efficiency. So, how do we keep the efficiency consistent?
The Key to Maintaining Efficiency
The best way to maintain cutting efficiency is to alternate cutting between hard and soft blocks. Specifically, after cutting one hard block, arrange to cut 2-3 soft blocks to keep the diamond sharp. When diamond wires continuously cut hard blocks, the diamonds wear down through abrasive wear, leading to decreased cutting efficiency (see figure 1).
Understanding Efficiency Reduction
To understand how much efficiency has been reduced, we can analyze cutting reports under different conditions:
1. Cutting Efficiency Comparison:
- The cutting efficiency of Silver Pearl (hardness level-3) was compared before and after cutting two hard materials (Viscount White, hardness level-5). The efficiency dropped from 0.86 to 0.78, a decrease of 9.3%.
2. Cutting Order Analysis:
- Another set followed the cutting order of soft → hard → soft. The cutting efficiency remained largely unaffected, with only a slight decrease of 2.8%, which is negligible for practical purposes. This indicates that the diamond remains sharp and cutting efficiency is high.
Conclusion: Importance of a Reasonable Cutting Arrangement
A reasonable cutting arrangement is crucial to maintaining the diamond's sharpness in the wire. Continuously cutting hard blocks will dull the diamond, reducing cutting efficiency by at least 10%, meaning an extra hour spent on cutting. Additionally, a dull diamond leads to issues with mark slabs, increasing grinding costs.
Therefore, keeping the diamond sharp through a strategic cutting sequence is essential. By alternating between hard and soft blocks, you ensure high cutting efficiency and lower overall production costs.