Abstract To further enhance productivity, numerous studies have focused on improving the economic efficiency of stone processing. Beyond increasing material output and reducing waste costs, diamond manufacturers, machine tool builders, and tool suppliers are working to boost the performance of their equipment. A significant amount of research has been dedicated to optimizing tool compatibility. One study evaluated 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. Generally, when the cutting depth exceeds 25 mm, it becomes impractical for granite processing due to excessive heat generation and potential overload on the diamond tools.
A collaboration involving a diamond partner, a diamond tool manufacturer, a machine tool builder, a saw blade matrix producer, and a European research institute was initiated to explore new frontiers in stone processing. The project emphasizes problem-solving, along with a comprehensive evaluation of technology, economics, and environmental impact. The main objective is to develop subsystems capable of handling deep-cut conditions—cutting depths ranging from 100 to 300 mm. This includes an advanced diamond circular saw blade and an improved lubrication system at the tool-workpiece interface, ensuring stable operation over time. This stability is crucial for highly automated processes. The research is conducted in two phases:
1. Conducting laboratory tests to collect essential 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 saw blade agglomeration, lubrication, and finishing systems) based on the findings from the first phase. In the initial phase, a key aspect of the project was using a small saw blade simulation to analyze machining forces, interface temperature (grinding zone), and vibration characteristics. When using a small blade, it's essential that the system aligns with real-world industrial conditions. To achieve this, many researchers have proposed various sawing models. Two primary variables in the system are cutting speed (Vc) and cutting depth (ae). By using these parameters and information on tool geometry, 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 the lab to measure the heat and forces generated in the cutting zone. This data is vital for determining lubrication systems for large-scale saws and predicting the forces diamond tools can endure. High-strength diamonds with a particle size of 30/40 and a density of 660 ± 30 per carat were used. First, medium-hard Italian granite was cut, followed by more challenging Indian red granite, one of the toughest materials to process. During the test, the cutting depth was kept at 90 mm, while the feed rate varied between 100 cm²/min (mild conditions) and 600 cm²/min (severe conditions), covering the industrial production range of 380–1000 cm²/min. Temperature measurements showed that as cutting speed increased, so did the temperature, but even at maximum speeds, it remained below 200°C. A dynamometer was used to measure normal and tangential forces, aiding in the design of sawmills and tool sizes for larger applications. Analyzing the cutting forces and studying the diamond wear process revealed that the work should be done within specific process limits to ensure uniform wear and proper diamond exposure, which is essential for effective material removal.
Requirements for Deep Granite Sawn Processing
Based on the data from the first phase, specialized equipment for deep sawing was designed. The focus was on the diamond saw blade, considering the following design requirements: the tool specifications and processing conditions must ensure that chip thickness matches the material removal rate and diamond exposure height. In deep sawing, unlike situations where chip thickness is too small, the main concern is when cutting parameters are too high, leading to chip thickness exceeding the exposed diamond height. This can cause diamond particles to fracture, resulting in insufficient gap between the workpiece and bonding agent, and ultimately, catastrophic failure. This increases normal force and leads to tool failure. Additionally, the project plan addresses factors like machine stability and lubrication power, which are critical during the final assembly of the deep saw.
A collaboration involving a diamond partner, a diamond tool manufacturer, a machine tool builder, a saw blade matrix producer, and a European research institute was initiated to explore new frontiers in stone processing. The project emphasizes problem-solving, along with a comprehensive evaluation of technology, economics, and environmental impact. The main objective is to develop subsystems capable of handling deep-cut conditions—cutting depths ranging from 100 to 300 mm. This includes an advanced diamond circular saw blade and an improved lubrication system at the tool-workpiece interface, ensuring stable operation over time. This stability is crucial for highly automated processes. The research is conducted in two phases:
1. Conducting laboratory tests to collect essential 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 saw blade agglomeration, lubrication, and finishing systems) based on the findings from the first phase. In the initial phase, a key aspect of the project was using a small saw blade simulation to analyze machining forces, interface temperature (grinding zone), and vibration characteristics. When using a small blade, it's essential that the system aligns with real-world industrial conditions. To achieve this, many researchers have proposed various sawing models. Two primary variables in the system are cutting speed (Vc) and cutting depth (ae). By using these parameters and information on tool geometry, 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 the lab to measure the heat and forces generated in the cutting zone. This data is vital for determining lubrication systems for large-scale saws and predicting the forces diamond tools can endure. High-strength diamonds with a particle size of 30/40 and a density of 660 ± 30 per carat were used. First, medium-hard Italian granite was cut, followed by more challenging Indian red granite, one of the toughest materials to process. During the test, the cutting depth was kept at 90 mm, while the feed rate varied between 100 cm²/min (mild conditions) and 600 cm²/min (severe conditions), covering the industrial production range of 380–1000 cm²/min. Temperature measurements showed that as cutting speed increased, so did the temperature, but even at maximum speeds, it remained below 200°C. A dynamometer was used to measure normal and tangential forces, aiding in the design of sawmills and tool sizes for larger applications. Analyzing the cutting forces and studying the diamond wear process revealed that the work should be done within specific process limits to ensure uniform wear and proper diamond exposure, which is essential for effective material removal.
Requirements for Deep Granite Sawn Processing
Based on the data from the first phase, specialized equipment for deep sawing was designed. The focus was on the diamond saw blade, considering the following design requirements: the tool specifications and processing conditions must ensure that chip thickness matches the material removal rate and diamond exposure height. In deep sawing, unlike situations where chip thickness is too small, the main concern is when cutting parameters are too high, leading to chip thickness exceeding the exposed diamond height. This can cause diamond particles to fracture, resulting in insufficient gap between the workpiece and bonding agent, and ultimately, catastrophic failure. This increases normal force and leads to tool failure. Additionally, the project plan addresses factors like machine stability and lubrication power, which are critical during the final assembly of the deep saw.
Shower Door
Shower Door
Guangzhou Aijingsi Sanitary Products Co.,Ltd , https://www.infinityedgehottub.com