Effect of rock properties on wear and cutting performance of multi blade circular saw with iron based multi-layer diamond segments
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2024-02-26 |
| Journal | Scientific Reports |
| Authors | Sohan Singh Rajpurohit, Yewuhalashet Fissha, Rabindra Kumar Sinha, Mujahid Ali, Hajime Ikeda |
| Institutions | Indian Institute of Technology Dhanbad, LuleÄ University of Technology |
| Citations | 3 |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: High-Performance Diamond Segments for Granite Sawing
Section titled âTechnical Documentation & Analysis: High-Performance Diamond Segments for Granite SawingâReference Paper: Rajpurohit et al. (2024). Effect of rock properties on wear and cutting performance of multi-blade circular saw with iron based multi-layer diamond segments. Scientific Reports.
Executive Summary
Section titled âExecutive SummaryâThis study provides critical insights into the tribological performance of multi-layer diamond segments used in large-scale granite sawing, directly informing material selection for extreme abrasive environments.
- Core Achievement: Developed highly accurate Multiple Linear Regression (MLR) models (Adjusted R2 up to 0.99) to predict diamond segment Wear Rate (WR) and Cutting Rate (CR) based on granite rock properties.
- Material System: Utilized Iron (Fe) based Metal Matrix Composite (MMC) multi-layer diamond segments brazed onto large circular saw blades (up to 2300 mm diameter).
- Key Performance Drivers: Sawing performance is overwhelmingly governed by rock strength, hardness, and abrasivity, specifically Point Load Strength Index (PLSI), Cerchar Abrasivity Index (CAI), Uniaxial Compressive Strength (UCS), and Modulus of Elasticity (E).
- Wear Mechanism Confirmation: FESEM analysis confirmed that wear is dominated by abrasion, erosion, and impact fatigue, leading to diamond grain polishing, micro-fracture, macro-fracture, and pull-out.
- Critical Correlation: PLSI showed the strongest positive linear relationship with Wear Rate (R2 = 0.90), emphasizing that stronger rock requires tougher, more wear-resistant diamond materials.
- Design Implication: The multi-layer segment design (alternating hard cutting layers and softer debris-removal layers) successfully mitigated polishing and facilitated debris removal, optimizing tool life and cutting efficiency.
Technical Specifications
Section titled âTechnical SpecificationsâThe following hard data points were extracted from the experimental setup and results, focusing on material and performance metrics.
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Max Saw Blade Diameter | 2300 | mm | Commercial multi-blade circular saw setup |
| Blade Core Thickness | 6.5 | mm | 75Cr1 grade steel core |
| Segment Dimensions | 24 x 15 x 8.6 | mm | Typical fresh multi-layer diamond segment |
| Diamond Grit Size | 40/50 | US mesh | Used in the primary self-sharpening cutting layers |
| Segment Matrix | Fe-based | MMC | Metal Matrix Composite used for bonding |
| Segment Strength (Range) | 130 to 140 | Newtons | Crucial factor determining cutting ability |
| Max Cutting Rate (CR) Observed | 11.11 | m2/h | Granite S7 (Lowest strength/hardness) |
| Max Wear Rate (WR) Observed | 13.462 | ”m/m2 | Granite S2 (High strength/hardness) |
| Min Wear Rate (WR) Observed | 5.069 | ”m/m2 | Granite S6 (Low strength/hardness) |
| MLR Model R2 (Cutting Rate) | 0.9243 | Adjusted R2 | Model based on PLSI, E, BTS, CHI |
| MLR Model R2 (Wear Rate) | 0.9894 | Adjusted R2 | Model based on PLSI, CAI, UCS, E |
Key Methodologies
Section titled âKey MethodologiesâThe experimental procedure combined large-scale industrial sawing tests with detailed laboratory material analysis and advanced statistical modeling.
- Workpiece Selection: Nine varieties of large-sized granite blocks (S1 to S9) were selected, and their physico-mechanical properties (UCS, BTS, PLSI, CAI, CHI, E, etc.) were quantitatively determined using ISRM standard test methods.
- Tool Setup: A commercial multi-blade circular saw (65 kW motor) was used, comprising 10 blades with varying diameters (500 mm to 2300 mm).
- Segment Fabrication: Multi-layer diamond segments were commercially manufactured using powder metallurgy, mixing synthetic diamond grits (40/50 US mesh) with Iron (Fe) based Metal Matrix Composites (MMC). Layers alternated between hard, diamond-containing cutting layers and softer, diamond-free layers for debris removal.
- Sawing Parameters: Sawing was performed in alternate up-cutting and down-cutting modes.
- Feed Speed: 50-100 mm/s.
- Sawing Depth: 20-25 mm per pass.
- Spindle Speed: 343 revolutions per minute (constant).
- Performance Measurement: Cutting Rate (CR, m2/h) and Wear Rate (WR, ”m/m2) were calculated based on total sawn area and macroscopic linear wear progression (segment height reduction).
- Microscopic Analysis: Segment wear progression and matrix composition were studied using Field Emission Scanning Electron Microscopy (FESEM) and Energy Dispersive X-ray (EDS) analysis to confirm elemental composition (Fe, Cu, C, O, Ti, etc.) and wear modes.
- Statistical Modeling: Statistical Machine Learning (MLR, Random Forest Regression, PCA) was used to correlate rock properties with CR and WR, identifying PLSI, CAI, CHI, and E as the most significant variables.
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThe research highlights the critical need for diamond segments optimized for extreme abrasion and impact fatigue in hard rock processing. 6CCVDâs advanced MPCVD diamond technology provides the ideal platform for replicating and extending this high-performance application.
Applicable Materials for Enhanced Performance
Section titled âApplicable Materials for Enhanced PerformanceâThe paper utilized sintered PCD/MMC segments. For next-generation tools requiring superior thermal stability, toughness, and wear resistance in high-impact, abrasive environments like granite sawing, 6CCVD recommends:
| 6CCVD Material | Specification | Application Advantage |
|---|---|---|
| High-Toughness PCD | Polycrystalline Diamond (PCD) plates up to 125mm diameter. | Offers superior fracture toughness and thermal stability compared to conventional sintered segments, resisting the macro-fracture and pull-out wear modes observed in the study. |
| SCD Substrates | Single Crystal Diamond (SCD) up to 500 ”m thickness. | For micro-tooling or specialized segments requiring ultra-high purity and hardness to resist polishing wear when cutting extremely hard, low-abrasivity granites (e.g., S3, S7). |
| Custom BDD | Boron-Doped Diamond (BDD) films. | While not directly used for cutting, BDD offers exceptional electrochemical stability, ideal for sensor or electrode applications related to monitoring slurry chemistry or tool condition monitoring in the abrasive environment. |
Customization Potential for Segment Manufacturing
Section titled âCustomization Potential for Segment Manufacturingâ6CCVDâs in-house capabilities directly address the custom requirements inherent in multi-blade saw segment design:
- Custom Dimensions: We supply MPCVD PCD plates and wafers up to 125 mm in diameter, allowing manufacturers to laser-cut or shape segments to match the exact 24 mm x 15 mm x 8.6 mm dimensions (or any custom size) required for specific blade diameters (500 mm to 2300 mm).
- Thickness Control: We offer precise PCD thickness control from 0.1 ”m to 500 ”m, enabling the creation of multi-layer structures with optimized diamond concentration profiles, mimicking the hard/soft layer approach described in the paper.
- Advanced Metalization: The paper relies on an Fe-based MMC matrix. 6CCVD offers internal metalization services (Au, Pt, Pd, Ti, W, Cu) to apply adhesion layers directly onto the PCD surface. This ensures superior chemical bonding and thermal stability between the diamond segment and the customerâs chosen metal matrix (e.g., Fe-MMC or Co-based alloys), mitigating segment pull-out and enhancing segment strength (130-140 N range).
Engineering Support
Section titled âEngineering SupportâThe successful predictive modeling in this research relies on correlating complex rock properties (PLSI, CAI, UCS) with tool performance. 6CCVDâs in-house PhD team specializes in diamond material science and tribology.
We offer consultation services to assist engineers and scientists in selecting the optimal MPCVD diamond grade (SCD or PCD) and segment geometry based on application-specific tribological data, such as:
- Abrasivity Matching: Analyzing customer rock data (CAI, CHI) to recommend the appropriate diamond grain size and PCD toughness required to synchronize diamond wear and matrix erosion, ensuring continuous self-sharpening.
- Impact Resistance: Optimizing PCD thickness and substrate material to maximize resistance against impact fatigue and cleavage fracture observed during high-speed granite cutting.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
Tech Support
Section titled âTech SupportâOriginal Source
Section titled âOriginal SourceâReferences
Section titled âReferencesâ- 2017 - Tribology: Friction and Wear of Engineering Materials