In a complex project to dismantle the fourth largest blast furnace at a steel mill, we faced several unique challenges. The total construction period was three months, and the initial task was to cut off the cross beam connecting the blast furnace to the steelmaking plant. This article details the problems encountered and the solutions applied during the diamond wire cutting process.
Challenges and Solutions in Diamond Wire Cutting
1. Lack of Platform for Diamond Wire Connection
Challenge:
The cutting beam was suspended below the cutting platform, making it difficult to connect the diamond wire. The process required workers to hang and manually thread the rope, which was time-consuming and risky.
Solution:
Implementing the use of guide wheels significantly reduced the workload. By strategically placing guide wheels, the rope threading process became more efficient and safer.
2. Difficulty in Installing Guide Wheels
Challenge:
The installation of guide wheels was problematic due to site conditions and material shortages. A considerable amount of time was spent on this task, impacting overall project efficiency.
Solution:
Despite the challenges, the application of guide wheels proved essential. Their use minimized the contact area for the diamond wire, reducing wear and tear and improving cutting precision.
3. Insufficient Water Supply
Challenge:
The suspended position of the cutting beam meant that water added for cooling would drain away quickly. The internal structure was primarily steel plates with a concrete surface layer, limiting effective water distribution and cooling.
Solution:
Water pipes were placed at both the inlet and outlet ports to maximize cooling. Although the water supply was not ideal, this setup helped maintain the efficiency and longevity of the diamond wire.
4. Diamond Wire Shaking
Challenge:
The instability of the cutting beam's internal structure caused the diamond wire to shake, especially when transitioning between cutting steel plates and concrete. This shaking reduced cutting accuracy and efficiency.
Solution:
To stabilize the wire, we used machine controls to adjust the walking speed and installed additional guide wheels. Supporting materials like wood were also used to mitigate shaking.
5. Suboptimal Efficiency and Longevity of Diamond Wire
Challenge:
The initial choice of the SRC105E diamond wire was not suitable for the high-purity, thick steel beams. The equipment and wire experienced significant shaking, and the lack of adequate cooling water further degraded performance.
Solution:
Switching to the ST110E diamond wire for steel cutting improved overall performance. This wire proved more effective for the specific conditions of the project, providing better efficiency and durability.
Case Summary
The experience from this project highlights several important considerations for diamond wire cutting in complex environments:
- Assess Internal Structure: Understanding the internal composition of the cutting object is crucial for selecting the right tools and techniques.
- Optimize Site Setup: Proper setup, including the use of guide wheels and effective water cooling, can significantly impact cutting efficiency.
- Adapt Equipment: Choosing the right diamond wire and adjusting machine settings based on real-time performance can enhance project outcomes.
- Monitor and Adjust: Continuous monitoring and adjustment of the wire and guide wheel positions are essential to maintain optimal performance and reduce resistance.
By considering these factors, you can improve the efficiency and effectiveness of diamond wire cutting projects, ensuring timely and high-quality results.