Damage and failure evaluation of diamond wire for multi-wire sawing of hard stone blocks through modelling and numerical simulation
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2021-01-01 |
| Journal | MATEC Web of Conferences |
| Authors | Daniel Gomes, Andreia AraĂșjo, R. MarquĂȘs, JosĂ© PatrĂcio, VĂtor Lopez |
| Institutions | Universidade do Porto, Institute of Mechanical Engineering and Industrial Mangement |
| Citations | 2 |
| Analysis | Full AI Review Included |
Technical Analysis and Documentation: High-Performance Diamond for Stone Sawing Wire
Section titled âTechnical Analysis and Documentation: High-Performance Diamond for Stone Sawing WireâThis documentation analyzes the research paper âDamage and failure evaluation of diamond wire for multi-wire sawing of hard stone blocks through modelling and numerical simulationâ and connects the findings to the advanced material solutions offered by 6CCVD.
Executive Summary
Section titled âExecutive SummaryâThis study utilizes Finite Element Analysis (FEA) to model the mechanical behavior and failure mechanisms of diamond wire used in high-speed, multi-wire stone cutting (e.g., granite). The findings confirm the extreme mechanical demands placed on the diamond beads, reinforcing the necessity for high-performance MPCVD diamond materials.
- Core Achievement: Development and validation of a 3D numerical model (Abaqusâą) representing the 7x7 steel wire rope, hyperelastic TPU coating, and diamond bead assembly.
- Validation Success: The numerical model achieved high accuracy, demonstrating an error smaller than 6% relative to experimental tensile tests.
- Extreme Load Case: Simulation applied combined mechanical solicitations: 2000 N maximum tension, 1.5 turns/meter pre-torsion, and bending stress (780 mm pulley diameter).
- Critical Stress Points: Maximum von Mises equivalent stresses reached 1200 MPa on the top wires of the steel rope due to the superposition of tension and bending.
- Failure Mechanism Insight: Stress concentration was identified in the TPU coating at the bead fillet, confirming this as a critical point for service life reduction.
- Material Implication: The high mechanical loads and complex stress distributions necessitate diamond beads manufactured from materials with exceptional fracture toughness and wear resistance, such as advanced MPCVD Polycrystalline Diamond (PCD).
Technical Specifications
Section titled âTechnical SpecificationsâThe following hard data points were extracted from the numerical simulation and experimental context described in the paper:
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Wire Rope Construction | 7x7 | Lay | Right regular lay, 49 individual wires |
| Wire Rope Youngâs Modulus (E) | 180 000 | MPa | Steel cable material property |
| Wire Rope Yield Stress (Rp0.2) | 2160 | MPa | Steel cable material property (Perfectly Plastic Model) |
| Diamond Wire Model Length | 27 | mm | Represents the pitch between consecutive beads |
| Polymer Coating Material | Thermoplastic Polyurethane (TPU) | N/A | Modeled using Van der Waals hyperelastic model |
| Maximum Applied Tension | 2000 | N | Maximum load during cutting operation |
| Standard Applied Torsion | 1.5 | turns/meter | Pre-torsion during cable production |
| Equivalent Angular Deformation | 9.42 | rad/m | Corresponds to 1.5 turns/meter torsion |
| Smallest Pulley Diameter | 780 | mm | Hedel machine, dictates highest bending stress |
| Maximum Von Mises Stress (Wire) | 1200 | MPa | Observed on top wires due to tension/bending superposition |
| Standard Torsion Torque | 861 | Nmm | Resulting torque from 1.5 turns/meter pre-torsion |
| Model Validation Error | < 6 | % | Relative error compared to experimental tensile test |
Key Methodologies
Section titled âKey MethodologiesâThe numerical simulation focused on accurately modeling the complex geometry and mechanical interactions within the diamond wire assembly under operational loads.
- 3D Geometry Definition: The 7x7 right regular lay wire rope (49 individual wires) was modeled in Solidworksâą using helical paths. The model length was set to 27 mm to represent a single bead pitch.
- FEA Software: Finite Element Analysis was conducted using Abaqusâą software.
- Wire Rope Constraint: A specialized tie constraint was applied between the outer wires and the core strand to simulate the tightening tension during production, eliminating non-physical gaps and ensuring the model stiffness matched analytical predictions (Costello model).
- Material Modeling:
- Steel wire rope: Modeled with E = 180 000 MPa and Rp0.2 = 2160 MPa, assuming perfectly plastic deformation.
- TPU coating: Modeled as a hyperelastic elastomer, with the Van der Waals model selected for optimal balance between accuracy and computational efficiency.
- Diamond Bead Integration: The diamond bead geometry was incorporated by extruding a hollow circular profile (4.4 mm OD, 2.16 mm ID) for the polymer coating, followed by Boolean operations to define the negative geometry of the wire rope and the diamond bead.
- Sequential Load Application: The complex cutting loads were applied in three consecutive steps to isolate their influence:
- Step 1: 2000 N point load (Traction).
- Step 2: Angular displacement of 0.1272 radians (Torsion).
- Step 3: Orthogonal displacement of 0.23 mm (Bending stress).
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThe research highlights that the limiting factor in diamond wire service life is often mechanical failure driven by high stress and fatigue, rather than just abrasive wear. 6CCVD provides advanced MPCVD diamond materials engineered to withstand these extreme conditions, enabling longer service life and higher cutting speeds for hard stone applications.
Applicable Materials
Section titled âApplicable MaterialsâTo replicate or extend this research, particularly focusing on improving the mechanical durability and wear resistance of the diamond bead itself, 6CCVD recommends the following materials:
| Material Grade | Description & Application | Relevance to Research |
|---|---|---|
| High-Toughness Polycrystalline Diamond (PCD) | MPCVD PCD wafers optimized for industrial cutting tools. Offers superior fracture toughness and thermal stability compared to traditional HPHT or sintered materials. | Essential for resisting the high combined mechanical stresses (up to 1200 MPa) and fatigue identified in the wire rope assembly. Maximizes bead life in granite and hard stone sawing. |
| Optical Grade Single Crystal Diamond (SCD) | High-purity, low-defect SCD plates. Used for specialized, ultra-high precision cutting applications where minimal friction and maximum thermal dissipation are required. | Suitable for R&D or specialized beads where the highest possible material hardness and thermal conductivity are prioritized to reduce localized thermal stress. |
Customization Potential
Section titled âCustomization PotentialâThe paper models a specific bead geometry (4.4 mm OD). 6CCVDâs manufacturing capabilities are perfectly suited to supply the raw material and perform the necessary post-processing for custom diamond bead production.
| Requirement from Research | 6CCVD Capability | Technical Specification |
|---|---|---|
| Custom Dimensions | Supply of large-area PCD wafers for high-volume bead manufacturing. | Plates/wafers available up to 125 mm (PCD). |
| Precision Shaping | Advanced laser cutting and shaping services. | Precision laser cutting to achieve complex bead geometries and internal diameters (e.g., 4.4 mm OD) with high tolerance. |
| Surface Finish | Ultra-precision polishing to reduce friction and heat generation. | Polishing capability of Ra < 5 nm for inch-size PCD, minimizing stress concentration points. |
| Substrate Thickness | Ability to supply robust diamond layers for durable beads. | SCD/PCD thickness ranging from 0.1 ”m up to 500 ”m. |
Engineering Support
Section titled âEngineering SupportâThe detailed FEA work presented in this paper requires precise material inputs for accurate simulation. 6CCVDâs in-house PhD team specializes in the mechanical, thermal, and electronic properties of MPCVD diamond.
- Material Data Provision: We assist engineers replicating similar FEA work by providing verified material parameters (e.g., Youngâs Modulus, fracture toughness, thermal expansion coefficients) specific to our SCD and PCD grades.
- Application Optimization: Our experts offer consultation on material selection and geometry optimization for high-load applications like multi-wire stone sawing, ensuring the diamond bead design maximizes resistance to the identified stress concentrations (tension, torsion, bending).
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
Diamond wires are high-speed, efficient and cost-effective stone cutting tools used both in quarries, to obtain large stone blocks, and in block-processing plants, to shape ornamental stones. Diamond wires are generally composed by a wire rope with evenly spaced diamond beads fixed by a polymer or rubber coating. A numerical model of the diamond wire was developed in Abaqusâą software aiming to study the damage and failure of the steel wire during the cutting process. The model is intended to support the development of this component with enhanced durability and damage resistance. Previously in this work, a detailed three-dimensional (3D) and numerical model of a 7x7 wire rope was created, followed by experimental validation. The diamond wire model was then based on the wire rope model, with the addition of the polymer coating and the diamond beads. The developed diamond wire model presents an error smaller than 6% relative to the experimental tensile test, corresponding to a valid representation of the component. This model has practical significance for the mechanical evaluation of the diamond wire, supporting further developments, with special focus on its design and manufacturing, to achieve longer service life.