Energy consumption and wear rate of diamond beads during operation of a diamond wire saw
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2023-12-12 |
| Journal | E-Zbornik elektroniÄki zbornik radova GraÄevinskog fakulteta |
| Authors | Tomislav Korman, Trpimir KujundĆŸiÄ, Ć ime VrandeÄiÄ |
| Institutions | University of Zagreb |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: Diamond Wire Saw Efficiency and Wear Rate
Section titled âTechnical Documentation & Analysis: Diamond Wire Saw Efficiency and Wear RateâReference Paper: Korman, T., KujundĆŸiÄ, T., VrandeÄiÄ, Ć . (2023). Energy consumption and wear rate of diamond beads during operation of a diamond wire saw. e-ZBORNIK, Special Issue.
Executive Summary
Section titled âExecutive SummaryâThis documentation analyzes the factors influencing the efficiency and wear rate of diamond beads in Diamond Wire Saws (DWS), a critical process in dimension stone extraction. The findings underscore the necessity of high-quality, application-specific diamond materials, aligning directly with 6CCVDâs core capabilities in MPCVD diamond synthesis.
- Core Challenge: Maximizing DWS efficiency (m2/h) while minimizing specific energy consumption and diamond bead wear (”m/m2).
- Efficiency Drivers: Sawing efficiency is governed by a complex interplay of uncontrolled parameters (rock strength, hardness, abrasiveness, quartz content) and controlled parameters (machine design, operating values).
- Material Specification: Standard industrial applications utilize synthetic SDA-type diamond grit (e.g., 40/50 mesh, 35% concentration) within sintered cylindrical beads.
- Wear Correlation: Bead wear is highly correlated with rock abrasiveness, uniaxial compressive strength, and excessive traction force, often resulting in conical wear patterns in hard materials like granite.
- Optimal Assembly: Optimal efficiency in travertine is achieved with 31 beads per meter of wire length, emphasizing the need for precise material assembly and design.
- 6CCVD Value Proposition: 6CCVD provides the high-purity Polycrystalline Diamond (PCD) and Single Crystal Diamond (SCD) required for developing next-generation, ultra-wear-resistant cutting segments and advanced laboratory testing platforms.
Technical Specifications
Section titled âTechnical SpecificationsâThe following hard data points were extracted from the analysis regarding DWS performance and material requirements:
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Sawing Efficiency (Soft Rock) | 5 to 12 | m2/h | Travertine and Marble |
| Sawing Efficiency (Limestone) | 5 to 7 | m2/h | Limestone Quarries |
| Optimal Beads per Meter | 31 | beads/m | Travertine cutting, middle third of bead lifetime |
| Diamond Grit Type | SDA (Synthetic) | N/A | Standard industrial application |
| Diamond Grit Size | 40/50 | mesh | Standard industrial application |
| Diamond Concentration | 35 | % | Standard industrial application |
| Example Bead Outer Diameter | 10 | mm | Cylindrical sintered bead |
| Example Bead Inner Diameter | 5 | mm | For 5 mm steel rope |
| Example Bead Length | 8.5 | mm | Cylindrical sintered bead |
| Optimal Saw-Face Distance (7m Bench) | 3 | m | Vertical cut geometry optimization |
| Optimal Saw-Face Distance (12m Bench) | 4.5 | m | Vertical cut geometry optimization |
| Optimal Cut Area Threshold | 60 | m2 | Threshold for adjusting wire tension/feed force |
| Specific Energy Prediction Accuracy | 85.8 | % | Developed using multiple regression analysis |
Key Methodologies
Section titled âKey MethodologiesâThe research analyzed the DWS process by focusing on the interaction between material properties and operational parameters, drawing heavily on laboratory and field studies:
- Parameter Categorization: All variables affecting sawing efficiency were divided into two groups: Uncontrolled (Rock Properties: strength, hardness, abrasiveness, quartz content, texture) and Controlled (Design Values: motor power, diamond size/type, beads per meter; Operating Values: linear wire speed, feed force, wire tension, cooling water flow).
- Specific Energy Measurement: Laboratory tests were conducted on various igneous and metamorphic rocks (diorite, granite, andesite) to measure specific cutting energy (SE). SE was found to correlate highest with rock density, abrasiveness, and p-wave velocity.
- Wear Rate Quantification: Specific wear (UW) of diamond beads was calculated by measuring the change in bead diameter (d0 - d1) before and after cutting, normalized by the sawn area (A).
- Formula: UW = (d0 - d1) / A (Unit: ”m/m2).
- Measurement: Micrometers and computer image processing of microscopic images were used to determine diameter change.
- Operational Optimization: Field tests analyzed the influence of cutting geometry (lateral vs. central horizontal cut), optimal distance between the saw and the bench face (1.5 m to 5.5 m), and the effect of traction force (45 A to 65 A feed motor current) on efficiency.
- Material Lifetime Analysis: Efficiency was tracked across the lifetime cycle of the diamond beads, showing peak efficiency often occurs in the middle third of the beadâs life.
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThe research highlights that the performance of diamond wire saws is fundamentally limited by the quality and design of the diamond beads, particularly their wear resistance against highly abrasive rock types (e.g., granite, high-quartz content limestone). 6CCVD offers advanced MPCVD diamond solutions necessary to push the boundaries of DWS efficiency, longevity, and precision monitoring.
Applicable Materials for Advanced DWS Tooling
Section titled âApplicable Materials for Advanced DWS ToolingâTo replicate or extend this research, particularly in developing ultra-hard, low-wear cutting segments or high-precision laboratory testing tools, 6CCVD recommends the following materials:
| 6CCVD Material | Application Focus | Key Benefit |
|---|---|---|
| Polycrystalline Diamond (PCD) | Next-generation sintered bead segments, high-wear applications, tool development. | Superior fracture toughness and thermal stability compared to traditional synthetic grit, leading to reduced specific wear (UW). Available in plates up to 125mm. |
| Single Crystal Diamond (SCD) | Ultra-low friction surfaces, high-precision laboratory cutting tools, reference standards. | Highest purity and hardness. Can be polished to Ra < 1nm for friction studies or used as substrates for specialized sensors. |
| Boron-Doped Diamond (BDD) | Real-time monitoring and sensing integration. | Excellent electrochemical properties. Can be metalized and integrated into the wire assembly to monitor cutting conditions (e.g., water quality, temperature, or strain) in real-time. |
Customization Potential for Research and Development
Section titled âCustomization Potential for Research and Developmentâ6CCVDâs in-house capabilities directly address the need for precise material control and custom geometry identified in the paper:
- Custom Dimensions: While the paper cites 10 mm OD beads, 6CCVD can supply custom PCD or SCD plates/wafers up to 125 mm in diameter and up to 500 ”m thick for segment fabrication, ensuring exact material specifications for R&D prototypes.
- Precision Polishing: For studies focused on minimizing friction and optimizing cutting angle, 6CCVD offers ultra-smooth polishing (Ra < 1nm for SCD, < 5nm for inch-size PCD), allowing researchers to isolate the effects of surface finish on sawing resistance.
- Advanced Metalization: The integration of sensors (e.g., BDD) or specialized contacts requires robust metalization. 6CCVD offers internal capabilities for depositing Au, Pt, Pd, Ti, W, and Cu layers, enabling the development of smart diamond wire assemblies for real-time data acquisition.
Engineering Support
Section titled âEngineering Supportâ6CCVDâs in-house PhD team specializes in the material science of diamond growth and application. We offer authoritative professional consultation to engineers and scientists working on similar diamond wire cutting and high-wear tooling projects. We assist in selecting the optimal diamond grade, thickness, and surface preparation to achieve target wear rates and efficiency metrics.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
Diamond wire saws are indispensable machines for the extraction and processing of dimension stones. The cutting speed, energy consumption and wear rate of the diamond beads are the most important factors in assessing the efficiency of a diamond wire saw. The parameters that influence the efficiency of the diamond wire saw can be divided into controlled and uncontrolled parameters. Uncontrolled parameters cannot be influenced directly and are related to the rock types and their properties such as strength, hardness and abrasiveness. Controlled parameters are related to the operating parameters and technical characteristics of the machine. The energy consumption and the service life of the diamond wire are directly related to the characteristics of the machine and the design of the diamond wire, such as the power of the drive motor, the diameter of the drive wheel, diamond grit size and the diameter of the wire. The operating parameters of the diamond wire saw, such as cutting speed, cutting surface, cutting angle, wire tension and cooling water flow, also have a significant influence. Based on previous studies, the influence of the above parameters on the consumption of energy and wear rate of diamond beads in the operation of a diamond wire saw was analyzed.