Abstract To further boost productivity, numerous studies have focused on enhancing the economic efficiency of stone processing. Beyond improving material output and reducing waste costs, diamond manufacturers, machine tool builders, and tool suppliers are working to increase the performance of their equipment. A significant amount of research has been conducted to optimize tool compatibility. One study examined the current production capacity of marble processing machines, revealing that the most efficient granite saws in Europe are only about 4% more productive than those used for marble. In general, when the cutting depth exceeds 25 mm, it is typically not suitable for granite due to excessive heat generation and potential overload on the diamond tools.
A collaboration involving a diamond partner, a tool manufacturer, a machine builder, a saw blade matrix producer, and a European research organization initiated a project aimed at exploring new frontiers in stone processing. The focus was on problem-solving, technological evaluation, economic feasibility, and environmental impact. The program's goal was to develop subsystems capable of handling deep-cutting conditions—cut depths ranging from 100 to 300 mm. This includes an advanced diamond circular saw blade and an improved lubrication system to ensure long-term stable operation, which is essential for highly automated processes. The research was carried out in two phases:
1. Conducting laboratory tests to collect fundamental data such as material properties, cutting forces, temperature, and vibration, which serve as critical inputs for machine and tool design.
2. Developing tools and machine components (such as blade agglomeration, lubrication systems, and finishing mechanisms) based on the findings from the first phase. In the initial stage, a key aspect of the project was using a small-scale saw blade simulation to analyze cutting forces, interface temperatures, and vibration characteristics. When using a small blade, it’s crucial that the system matches real-world industrial conditions. To achieve this, many researchers have proposed various sawing models. Two main variables were identified: cutting speed (Vc) and depth of cut (ae). By incorporating these parameters along with tool geometry information, a simplified model for circular saw blade cutting can be developed.
Measuring Cutting Temperature and Forces Under Deep Sawing Conditions
Deep sawing was tested in a lab setting to measure the heat and cutting forces generated in the cutting zone. This data is vital for designing lubrication systems for large-scale saws and predicting the forces that diamond tools can handle during processing. High-strength diamonds with a particle size of 30/40 and a count of 660 ± 30 per carat were used. First, medium-hard Italian granite was cut, followed by more challenging Indian red granite, one of the hardest materials. During the test, the cutting depth was kept at 90 mm, while the feed speed varied between 100 cm²/min (mild conditions) and 600 cm²/min (severe conditions), covering the industrial range of 380–1000 cm²/min. Temperature measurements showed that as sawing efficiency increased, so did the cutting temperature—but even at the highest speeds, the temperature remained below 200°C. A dynamometer was used to measure normal and tangential cutting forces, aiding in the development of sawmill designs and tool sizing for larger applications. The analysis of cutting forces and the study of diamond wear revealed that the process must be carefully controlled to maintain uniform wear and adjust the diamond exposure height needed for effective material removal.
Requirements for Deep Granite Sawing
Based on the findings from the first phase, specialized equipment for deep sawing was designed. The focus was on the diamond saw blade, with specific design requirements ensuring that chip thickness aligns with material removal rate and diamond exposure. In deep sawing, unlike shallow cuts where thin chips are ideal, the main concern is when cutting parameters are too high, leading to thick chips that exceed the exposed diamond height. This can cause excessive brittleness, insufficient gap between the workpiece and bonding agent, and ultimately catastrophic failure. Such failures result in increased normal force and tool damage. Additionally, the project considered factors like machine stability and lubrication power during the final assembly of the deep saw system.
A collaboration involving a diamond partner, a tool manufacturer, a machine builder, a saw blade matrix producer, and a European research organization initiated a project aimed at exploring new frontiers in stone processing. The focus was on problem-solving, technological evaluation, economic feasibility, and environmental impact. The program's goal was to develop subsystems capable of handling deep-cutting conditions—cut depths ranging from 100 to 300 mm. This includes an advanced diamond circular saw blade and an improved lubrication system to ensure long-term stable operation, which is essential for highly automated processes. The research was carried out in two phases:
1. Conducting laboratory tests to collect fundamental data such as material properties, cutting forces, temperature, and vibration, which serve as critical inputs for machine and tool design.
2. Developing tools and machine components (such as blade agglomeration, lubrication systems, and finishing mechanisms) based on the findings from the first phase. In the initial stage, a key aspect of the project was using a small-scale saw blade simulation to analyze cutting forces, interface temperatures, and vibration characteristics. When using a small blade, it’s crucial that the system matches real-world industrial conditions. To achieve this, many researchers have proposed various sawing models. Two main variables were identified: cutting speed (Vc) and depth of cut (ae). By incorporating these parameters along with tool geometry information, a simplified model for circular saw blade cutting can be developed.
Measuring Cutting Temperature and Forces Under Deep Sawing Conditions
Deep sawing was tested in a lab setting to measure the heat and cutting forces generated in the cutting zone. This data is vital for designing lubrication systems for large-scale saws and predicting the forces that diamond tools can handle during processing. High-strength diamonds with a particle size of 30/40 and a count of 660 ± 30 per carat were used. First, medium-hard Italian granite was cut, followed by more challenging Indian red granite, one of the hardest materials. During the test, the cutting depth was kept at 90 mm, while the feed speed varied between 100 cm²/min (mild conditions) and 600 cm²/min (severe conditions), covering the industrial range of 380–1000 cm²/min. Temperature measurements showed that as sawing efficiency increased, so did the cutting temperature—but even at the highest speeds, the temperature remained below 200°C. A dynamometer was used to measure normal and tangential cutting forces, aiding in the development of sawmill designs and tool sizing for larger applications. The analysis of cutting forces and the study of diamond wear revealed that the process must be carefully controlled to maintain uniform wear and adjust the diamond exposure height needed for effective material removal.
Requirements for Deep Granite Sawing
Based on the findings from the first phase, specialized equipment for deep sawing was designed. The focus was on the diamond saw blade, with specific design requirements ensuring that chip thickness aligns with material removal rate and diamond exposure. In deep sawing, unlike shallow cuts where thin chips are ideal, the main concern is when cutting parameters are too high, leading to thick chips that exceed the exposed diamond height. This can cause excessive brittleness, insufficient gap between the workpiece and bonding agent, and ultimately catastrophic failure. Such failures result in increased normal force and tool damage. Additionally, the project considered factors like machine stability and lubrication power during the final assembly of the deep saw system.
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