ANALYSIS OF THE WEAR MECHANISM OF DIAMOND GRAINS AT DIFFERENT CUTTING SPEEDS
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2025-01-01 |
| Journal | Naukovyi visnyk Donetskoho natsionalnoho tekhnichnoho universytetu |
| Authors | Andrii Sydorenko, Serhii Mykytenko |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: Optimization of Diamond Tool Wear in Granite Processing
Section titled âTechnical Documentation & Analysis: Optimization of Diamond Tool Wear in Granite ProcessingâThis document analyzes the research paper âAnalysis of the Wear Mechanism of Diamond Grains at Different Cutting Speedsâ to provide technical specifications and demonstrate how 6CCVDâs advanced MPCVD diamond materials (SCD and PCD) can be utilized to replicate, optimize, and extend this research in hard material processing.
Executive Summary
Section titled âExecutive SummaryâThis study successfully determined the optimal operational parameters for maximizing the efficiency and lifespan of diamond saw blades used in cutting hard granite.
- Core Finding: The optimal cutting speed for Kapustinsky granite is 30-35 m/s at a feed rate of 1.2 mm/rev.
- Mechanism: This regime achieves a critical balance between grain wear and effective self-sharpening (renewal), ensuring stable cutting performance.
- High Speed Failure: Speeds >35 m/s lead to intense mechanical destruction, increased cracking (up to 30%), and premature grain pull-out (up to 20%), drastically reducing tool life.
- Low Speed Failure: Speeds <25 m/s result in insufficient grain renewal, causing the grains to become polished or âglazedâ (>40% worn grains), which increases cutting forces and energy consumption.
- Economic Impact: Implementing the optimal regime is projected to reduce tool replacement costs by 15% and extend the diamond disk lifespan by 20-25%.
- 6CCVD Value: 6CCVD provides high-purity Polycrystalline Diamond (PCD) plates up to 125mm, offering superior consistency and thermal stability necessary for developing next-generation, high-performance cutting segments.
Technical Specifications
Section titled âTechnical SpecificationsâThe following hard data points were extracted from the experimental results and methodology described in the paper:
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Optimal Cutting Speed (V) | 30-35 | m/s | Achieves balanced grain renewal and efficiency |
| Optimal Feed Rate (f) | 1.2 | mm/rev | Recommended for stable operation with Kapustinsky granite |
| Tested Cutting Speed Range | 20-45 | m/s | Range used for wear mechanism analysis |
| Tested Feed Rates | 1.2, 1.6 | mm/rev | Variables tested for feed influence |
| Saw Blade Diameter | 600 | mm | Diameter of the diamond disk used |
| Drive Motor Power | 7.5 | kW | Power of the edging machine motor |
| Granite Slab Thickness | 20 | mm | Thickness of Kapustinsky granite processed |
| High Speed Failure Threshold | >35 | m/s | Leads to intense grain destruction and pull-out |
| Low Speed Failure Threshold | <25 | m/s | Leads to insufficient grain renewal (glazing) |
| Target Tool Lifespan Increase | 20-25 | % | Economic benefit of optimized regime |
| Target Cost Reduction | 15 | % | Reduction in tool replacement costs |
| Electron Microscopy Magnification | 200 | x | Used for micro-geometric wear analysis (LAICA) |
Key Methodologies
Section titled âKey MethodologiesâThe research employed a systematic approach to analyze the micro-geometric wear of diamond grains under varying operational conditions.
- Equipment and Material: Experiments were conducted on a specialized edging machine using a 600 mm diamond saw blade. The workpiece was high-hardness Kapustinsky granite.
- Tool Composition: Diamond segments were sourced from Wanlong (China). The metal binder matrix composition included: C (14%), O (2%), Fe (25%), Co (12%), Ni (2%), Cu (32%), Zn (10%), and Sn (3%).
- Experimental Procedure: Cutting runs lasted 4 hours, processing 20 mm thick granite slabs. Two primary feed rates (1.2 mm/rev and 1.6 mm/rev) were tested across six cutting speeds (20, 25, 30, 35, 40, and 45 m/s).
- Wear Analysis Sample Preparation: After each stage, three diamond segments were removed from the disk for post-mortem analysis.
- Micro-Geometric Analysis: Electron microscopy (LAICA, 200x magnification) was used to analyze the wear morphology of at least 30 diamond grains per segment.
- Grain Classification: Grains were categorized based on wear state:
- Unworn Grains (retained primary shape).
- Glazed/Worn Grains (lost sharp edges due to friction).
- Cracked/Fractured Grains (suffered micro-destruction).
- Pulled-out Grains (completely separated from the binder matrix).
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThe research highlights the critical need for highly consistent, thermally stable diamond material and robust bonding mechanisms to withstand the high mechanical and thermal stresses encountered during granite cutting. 6CCVDâs MPCVD diamond solutions are ideally suited to meet and exceed these requirements, enabling researchers and engineers to develop next-generation diamond tools.
Applicable Materials
Section titled âApplicable MaterialsâTo replicate or advance the performance of the diamond segments studied, 6CCVD recommends the following materials:
-
Polycrystalline Diamond (PCD) Plates:
- Application: Direct replacement or enhancement for traditional sintered segments. Our MPCVD PCD offers superior purity and thermal conductivity compared to standard high-pressure/high-temperature (HPHT) sintered diamond, leading to reduced thermal stress and improved resistance to micro-fracturing observed at high speeds (>35 m/s).
- Dimensions: We supply PCD plates up to 125mm in diameter, allowing for the fabrication of large, custom segments required for 600 mm saw blades.
- Thickness: Available in thicknesses from 0.1”m up to 500”m for the active diamond layer, mounted on a custom substrate (up to 10mm).
-
Single Crystal Diamond (SCD) Inserts:
- Application: For ultra-high precision or specialized R&D where maximum hardness and thermal stability are required. SCD inserts can be integrated into segment designs for localized, high-stress cutting points.
- Polishing: SCD can be polished to an exceptional surface roughness of Ra < 1nm, providing a perfect baseline for initial wear studies.
Customization Potential
Section titled âCustomization PotentialâThe paper identified grain pull-out as a major failure mode at high speeds, indicating a weakness in the diamond-binder interface. 6CCVD directly addresses this challenge:
| Customization Service | Relevance to Granite Cutting Research |
|---|---|
| Custom Metalization | We offer in-house deposition of adhesion layers (e.g., Ti, W, Cu, Pt) directly onto the PCD or SCD surface. This capability is crucial for optimizing the chemical bond between the CVD diamond and the customerâs specific metal binder (Fe-Co-Cu-Ni), significantly reducing grain pull-out and extending tool life in high-stress regimes. |
| Custom Dimensions & Laser Cutting | We provide PCD plates in custom sizes up to 125mm, which can be laser-cut to precise segment geometries required for R&D prototypes or specialized saw blade designs. |
| Custom Substrates | We can supply diamond layers on custom substrates (up to 10mm thick) to match the thermal expansion properties required by the specific metal binder system, further enhancing mechanical stability. |
Engineering Support
Section titled âEngineering Supportâ6CCVDâs in-house team of PhD material scientists specializes in optimizing diamond properties for extreme environments. We offer comprehensive engineering support for similar hard abrasive material processing projects.
We assist clients in:
- Selecting the optimal diamond grade (PCD grain size, SCD orientation) based on target material hardness (e.g., Kapustinsky granite).
- Designing custom metalization schemes to maximize grain retention and thermal dissipation.
- Consulting on surface preparation (polishing, Ra < 5nm for PCD) to ensure repeatable experimental results for micro-geometric wear analysis.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
The aim of this study is to investigate the wear mechanism of diamond grains at different cutting speeds and determine the optimal conditions to improve the efficiency of granite processing using diamond saw blades. The study considers both cutting speed parameters and feed rate to establish optimal operating conditions that achieve high productivity with minimal tool wear and an extended tool lifespan. The research was conducted using a specialized edging machine equipped with a 600 mm diamond saw blade. The object of study was Kapustinsky granite, characterized by high hardness and a complex microstructure. During the experiment, the wear of diamond grains was measured using electron microscopy after each cutting stage. Two main feed rate options were used: 1,2 mm/rev and 1,6 mm/rev. The cutting speed varied between 20 and 45 m/s. The results of the study showed that the optimal cutting speed for achieving balanced cutting efficiency and minimal diamond grain wear is 30-35 m/s. At these speeds, effective grain renewal is ensured, maintaining the cutting ability of the tool at a sufficient level. Higher speeds (above 35 m/s) lead to intense destruction of diamond grains, an increase in the proportion of cracked and worn grains, and a decrease in productivity and tool lifespan. Additionally, speeds below 25 m/s result in insufficient grain renewal, which also reduces cutting efficiency. Based on the results, the optimal cutting speed for working with Kapustinsky granite was determined to be 30-35 m/s at a feed rate of 1,2 mm/rev. Using these conditions ensures stable grain renewal, reduces tool wear, and improves processing efficiency. Practical recommendations derived from this study allow for a 15 % reduction in tool replacement costs, improve cutting process efficiency, and extend the lifespan of diamond saw blades by 20-25 %. This will help reduce overall production costs and improve the competitiveness of the stone processing industry. The scientific novelty of this study lies in analyzing the impact of different cutting speeds on the wear pattern of diamond grains and determining optimal operating conditions to reduce energy consumption and improve the productivity of hard material processing. The recommended regimes can be applied to enhance technological processes in the stone processing industry, which is an important factor for improving economic efficiency and the quality of natural stone processing. Keywords: diamond grains, cutting speed, wear, cutting efficiency, granite processing, diamond tools, optimal conditions, stone processing industry.