Experimental Analysis of Abrasive Diamond Tool Wear and their Cutting Force in Stone Machining Process

At a Glance

Metadata	Details
Publication Date	2021-07-31
Journal	International Journal for Research in Applied Science and Engineering Technology
Authors	N. Balasubramanyam
Analysis	Full AI Review Included

Technical Documentation & Analysis: Abrasive Diamond Tool Wear in Stone Machining

Executive Summary

This analysis focuses on the experimental investigation of abrasive wear in Polycrystalline Diamond (PCD) cutting discs used for granite machining. The findings validate the critical role of high-quality, uniformly distributed diamond material in achieving predictable tool life and optimizing operational costs.

Application Focus: Wear analysis of industrial diamond segments (PCD) utilized in large-scale granite cutting operations (stone machining).
Core Finding: A strong linear relationship was confirmed between diamond segment material loss (weight and height) and total operational cutting time (100 hours).
Material Requirement: The study highlights the necessity of high-hardness, thermally stable PCD segments capable of withstanding extreme abrasive wear and high temperatures (up to 650 °C before graphitization).
Quantified Wear Rate: Over 100 hours, the tested discs experienced significant segment height loss, ranging from 48% (9.456 mm) to 55% (10.87 mm), demonstrating the high demands placed on the PCD material.
Process Optimization: Wear rates are highly dependent on the quality of the diamond particle dispersion within the metallic binder (Cobalt, Copper, Nickel, Iron) and precise control of cutting parameters (feed rate, speed, depth of cut).
6CCVD Value Proposition: 6CCVD provides high-purity MPCVD PCD wafers and plates, offering superior material consistency and customizable dimensions necessary for manufacturing next-generation, high-performance abrasive tools.

Technical Specifications

The following hard data points were extracted from the experimental setup and results, detailing the operational parameters and measured wear characteristics of the diamond cutting discs.

Parameter	Value	Unit	Context
Disc Diameter	500	mm	Standard industrial cutting wheel size
Segment Width	3.8	mm	Width of the PCD segment
Number of Segments	60	-	Total segments per disc
Rotation Speed (n)	1450	RPM	Saw operating condition
Perimeter Speed (V_p)	37.96	m/s	Calculated circumferential speed
Angular Speed (ω)	151,844	rad/min	Calculated angular velocity
Depth of Cut	8	mm	Constant cutting condition
Total Cutting Time	100	h	Total monitoring duration
Initial Segment Height (DISC-I)	19.581	mm	Initial height of segments
Total Height Loss (DISC-I)	10.87	mm	55% loss over 100 h
Total Height Loss (DISC-II)	9.456	mm	48% loss over 100 h
Graphitization Temperature	650	°C	Temperature at which diamond transitions to graphite when machining ferrous materials
PCD Synthesis Pressure	5.5	GPa	Pressure required for synthetic diamond production
PCD Synthesis Temperature	1350	°C	Temperature required for synthetic diamond production

Key Methodologies

The research focused on industrial-scale testing and material analysis of the diamond segments.

Diamond Segment Composition: Segments were composed of very small Polycrystalline Diamond (PCD) crystals, ranging in size from 150 µm to 1000 µm, dispersed within a metallic binder matrix.
Binder Material: Common metal elements used for the binder included Cobalt, Copper, Nickel, and Iron, utilizing fine dust particles (0.5 µm to 2 µm) to ensure free dispersion of diamond particles.
Disc Fabrication: The PCD segments were attached to the hardened steel core/carrier using one of three primary methods:
- Soldering: Melting solder between the core and segment at 600 °C to 800 °C.
- Laser Welding: Melting a thin layer of the steel core and segment to embed the diamond, allowing for dry cutting.
- Sintering: High-pressure pressing used to create a junction between the segment and the core’s microscopic teeth.
Experimental Procedure: Granite was cut using a formatting saw under consistent operating parameters (1450 RPM, 8 mm depth of cut).
Wear Quantification: The machine was halted periodically (over 100 total hours of cutting time) to measure wear. Wear was determined by measuring the total weight of the disc and the average height of the segments (measured every 5 to 10 teeth) after ensuring the disc was completely dry.

6CCVD Solutions & Capabilities

This research confirms the critical demand for high-quality, consistent PCD material in high-wear industrial applications. 6CCVD specializes in providing the foundational MPCVD diamond materials required to replicate or exceed the performance demonstrated in this study.

Applicable Materials

To achieve the uniform particle distribution and high mechanical strength required for superior abrasive tools, 6CCVD recommends:

Polycrystalline Diamond (PCD) Plates: Our MPCVD PCD offers exceptional purity and mechanical toughness, ideal for crushing and abrasive applications like stone cutting. We can supply PCD wafers up to 125 mm in diameter, providing the necessary feedstock for segment manufacturing.
Custom Thickness PCD: We offer PCD layers ranging from 0.1 µm up to 500 µm in thickness, allowing manufacturers to precisely control the diamond volume and segment geometry for specific cutting depths and materials (e.g., granite vs. marble).

Customization Potential

The fabrication of diamond segments requires precise material preparation and bonding capabilities, which 6CCVD supports directly:

Custom Dimensions and Shaping: While the final disc is 500 mm, 6CCVD provides the PCD material in custom plate sizes up to 125 mm, which can be laser-cut or shaped to match the required segment geometry (e.g., Normal, U, T, W, or Arix types shown in the paper).
Advanced Metalization Services: The study relies on bonding the diamond segment to a metallic binder (Co, Ni, Fe). 6CCVD offers in-house metalization services (including Ti, W, Pt, Au, Pd, Cu) to enhance adhesion and chemical stability between the diamond surface and the manufacturer’s chosen metal matrix, improving segment retention and reducing premature wear.
Polishing and Surface Preparation: We offer polishing services for PCD surfaces (Ra < 5 nm for inch-size plates), ensuring optimal surface preparation for subsequent sintering or laser welding processes used in segment attachment.

Engineering Support

The paper noted that wear lines varied between manufacturers, indicating differences in material quality and process control. 6CCVD’s in-house PhD team provides expert consultation to optimize material selection:

Abrasive Application Consulting: Our experts can assist tool manufacturers in selecting the optimal PCD grade and surface treatment to maximize tool life and minimize the high wear rates (up to 55% segment loss) observed in granite cutting.
Thermal Stability Analysis: We provide data on the thermal stability of our MPCVD diamond, crucial for applications where high tool heating (approaching the 650 °C graphitization limit) is a concern.
Global Supply Chain: We offer reliable global shipping (DDU default, DDP available) to ensure timely delivery of high-value diamond materials worldwide, supporting continuous industrial production.

For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.

View Original Abstract

Stone machining with a diamond tool is a common procedure for producing both standard items and design shapes, such as tiles, slabs and so on. During the entire deep sawing process of a granite work piece with finite length cutting procedure in stone processing, force components acted on the saw-blade. The work is split into two parts: theoretical and practical. The theoretical section discusses the features of diamond blades, cutting process methodology, and stone mining and processing methods. The practical portion of the project focuses on the wear of diamond blades when cutting stone, notably granite. The overall weight of the cutting blade and the loss of tooth height as a function of time are used to determine blade wear for two cutting blades from different manufacturers. There is a linear relationship between the two measured values. The findings serve as the foundation for a cost-benefit analysis of both diamond wheels.

Tech Support

Original Source

DOI: https://doi.org/10.22214/ijraset.2021.37057