The idea of ​​using diamond wire saws to mine stone was proposed by British DHProwse in 1968. The first utility machine was successfully developed in Italy in October 1977 by Luig Madrigali. In less than a few years, hundreds of sawing machines were produced, and more than 200 quarries in Italy promoted the use of wire saws. Therefore, the diamond bead wire saw was first used in Italy and was called the “marble mining revolutionâ€. At the S.Ambrogio Stone Fair in Verona, Italy, in 1969-1970, the beaded ropes and processing equipment with electroplated beading were exhibited for the first time. Since then, this promising tool has grown rapidly.
After 20 years of research and development, diamond wire saws are widely used not only for the exploitation of marble, but also for the separation and cutting of hard rock such as sandstone and granite; not only for open pit mining, but also for underground narrow veins and explosions. Dangerous mining of underground gold mines in South Africa; not only for the processing of shaped stone products, but also for the construction and construction of roads and the demolition and finishing of reinforced concrete.
The creative use of diamond bead wire saws in quarrying and construction projects has enabled diamond bead wire saws from quarry to stone processing plants, from bulk cutting to dressing, from sheet metal cutting to shaped products processing and construction applications. more and more.
Diamond wire saw is the third generation product in the development of diamond tools. After more than 20 years of research and development and improvement, it is widely used in various projects. This is mainly because it has the following advantages:
(1) The equipment is simple and easy to install. It is not subject to the limitation of space and space. It can cut horizontally, vertically and obliquely. The sawing area can reach 200m2, the processing quality is good, the stone loss is low, the cutting speed is fast, and the noise is low. The vibration work environment is good, the adaptability is strong, and the diamond wire saw equipment of different specifications and sizes can be selected according to the sawing object and the working condition.
(2) Significantly increase the rate of stone mining and protect precious stone resources.
(3) It can process granite and marble shaped products of various shapes with high added value, which can significantly improve economic benefits.
(4) It can extract large-sized blocks of large-sized blocks, increase the specifications of finished materials, and then increase the specifications of plate products of advanced stone processing equipment to improve cutting efficiency and economic benefits.
(5) The superiority of the above-mentioned diamond bead wire saw is undoubtedly a solution to the problem of low material rate in the stone industry in China, shortage of large-size plates, and the contradiction of the special-shaped products that cannot meet the requirements at home and abroad. Actively developing and promoting wire saws is an important part of developing China's stone industry.
Since the advent of the diamond wire saw, it has been a process of continuous innovation in the wire saw manufacturing process, and it is also the continuous development and expansion of the wire saw. At present, there are more than 2,000 wire saws in the world of mining marble, more than 1,000 wire saws for mining granite, and the number of wire sawing machines and sheet sawing machines are increasing, with wire saws as many as 50-100. It is used for building repair and maintenance, and the number of wire saws used in traffic engineering reconstruction is increasing. Studies have shown that diamond beading is still a major factor in the cost and effectiveness of diamond wire saw cutting. Therefore, a series of innovations have been made around the bead manufacturing process at home and abroad.
(1). Bead types form a variety of products for electroplating, sintering and high temperature brazing;
(2). KPV218 and WPD20 cold presses significantly improve the production efficiency of bead cold press, and the domestic manual cold press process is also constantly improved;
(3). The bead sintering process is continuously improved;
(4) beaded injection molding or vulcanized rubber;
(5). Application of high temperature brazing;
(6). The diamond wire saw develops to a small diameter;
(7). Production of small diameter diamond wire saws by powder plastic "online" processing technology;
(8). Wire saw blade, Dr. Fritsch has introduced the SAMl50 wire saw blade for this purpose, which can be used to edge 10-50m wire saws.
Building materials are very important to almost every part of our lives. A large number of materials of different nature are used depending on the specific use of the building. As these buildings require constant renovation and renovation, these materials require cutting and retrofitting with linear cutting tools. Wire saw sawing systems are widely used for sawing metal, stone and concrete. At the above site, the wire saw currently used is too large in size and difficult to operate. The reason for this is that the power rating of the transmission components is too large and the design is too cumbersome, so it is necessary to develop a particularly small wire saw sawing system. In order to develop an advanced wire saw system to meet the needs of the market, a joint initiative of leading European companies has been formed in the EC-based CRAFT project, not only for wire saw end users and research institutes, but also for equipment and tool manufacturing companies. Participated in the research project. The development of the new machine was mainly carried out by the wire saw system supplier CEDINA, Ferdinand Koller & Sohn and the University of Hanover's School of Production Engineering and Mechanical Tools. The Cedima wire saw system supplier is responsible for the design and development of various components of the new machine, especially the high frequency motor. The FerdinandKoBer&Shon manufacturing plant is responsible for the manufacture of the new wire saw machine. The bead wire saw is produced by the HB Diamond Wire Saw Factory. Robuco (wire saw user) fully supports the development and development of the entire wire saw system with its extensive knowledge and experience in wire sawing.
Small-sized saw-cut beads were assembled for the development of new small diamond wire saws. These smaller sized beadings cannot be manufactured using the usual cooling first, followed by high temperature hot pressing, which is now fully automated. The new manufacturing method used is the HIP hot isostatic pressing method.
As the diameter of the new wire saw is reduced, cobalt, which is a well-known toxic material, is reduced in the carcass. In small-diameter wire saws, cobalt, a material that is harmful to human health, is reduced by 75%, thereby reducing environmental pollution.
The test of sawing reinforced concrete with a fine wire saw and a common wire saw shows that compared with the commonly used wire saws with diameters of 11.5 mm and 8.5 mm, sawing with a wire saw with a diameter of 6.5 m (small) is compared due to feed pressure. Low, so its sawing power and energy consumption are much lower.
Compared with wire saws with a diameter of 11.5mm, the sawing force and energy consumption are reduced by 40%; compared with the diameter of 8.5mm wire saws, the sawing force and energy consumption are reduced by 30%.
Measurements of noise levels under different diameter wire saws indicate that the wire saw has a reduced diameter and a reduced noise level. The noise level also depends on the sawing speed, but its effect is not very large. The main influencing factor is the diameter of the wire saw. For the d-11mm wire saw, when the sawing speed Vc=16.7m/s, the noise at the far side of lm is 92dB (A). For medium-sized wire saws, the noise drop is 89 dB(A) at the same sawing speed. With a smaller diameter wire saw, the noise is about 87 dB(A). This means that with a smaller diameter wire saw, the noise drop can reach 5dB (A).
One of the most important findings from the test was that the use of a smaller diameter wire saw would significantly reduce the feed pressure. A wire saw that reduces the diameter by 25% will reduce the feed pressure by more than 25%. Compared with the operation of ordinary wire saws during sawing, the wear and deflection of the wire saw are reduced to the minimum level.
In summary, the wire saw saws currently used in construction sites are too large in construction and are not ergonomic in terms of ease of handling and handling. A small and lightweight multi-function wire saw saw is needed for this purpose. The newly developed wire sawing machine can complete the installation and operation of the whole system by one person. The various parts of the machine are easy to install and disassemble, and each part weighs no more than 25Kg. Thanks to the newly developed wire saw tool, the machine will produce less waste, lower noise and less pollution, which makes the wire saw machine superior performance.
The diamond wire saw was originally used only for the mining of natural stone. The first generation of diamond wire saw bead was electroplated and later developed into a sintered type. The diamond foot on the electroplated bead is held with a nickel binder; the diamond on the sintered bead is held with a metal binder such as cobalt. The former contains a layer of diamond, while the latter is a multi-layered diamond. The electroplated diamond bead has a faster cutting speed during the initial cutting stage, but it wears out very quickly, especially when cutting hard rock; the sintered diamond bead has a slower cutting speed but a very high life. On these two types of beads, the diamond is randomly distributed in the carcass and mechanically held. The disadvantage is that the diamond particles cannot be completely exposed for effective cutting, and they are also seriously depleted due to the pulling force. In addition, the random arrangement of diamond particles often makes the diamond distribution uneven, and as a result, in the region with high diamond concentration, many diamonds cannot be fully and effectively utilized, resulting in waste, and often block the chip evacuation channel; and in areas with low diamond concentration Some diamond particles are not reinforced by adjacent diamonds. The load is too heavy, so it is easy to break. Effective cutting is not possible.
Compared with the electroplated diamond bead wire saw, the hot-pressed diamond bead carcass has a large adjustment range of performance, and the carcass has strong holding power for diamonds, and is suitable for cutting hard cutting objects such as granite and reinforced concrete, and thus occupies 2 in the wire saw market. /3 share.
Practice has found that domestic research and development of hot-pressed diamond bead wire saws generally have the following problems:
(1). The performance of the carcass does not match the object of cutting. During the process of use, the diamond is seriously granulated, and the cutting efficiency and life span are far from the international advanced level.
(2). The beaded carcass is not firmly bonded to the substrate, and the phenomenon that the carcass part is lost and the whole body falls off is serious;
(3). The bead fixing effect is poor, and some beading has a phenomenon of rotating around the steel wire and striking along the axial direction of the steel wire rope;
(4). The wire rope is broken frequently and the service life is short;
In order to solve the problems in the process of use, Guo Hua et al., after extensive exploratory research, believe that the key technical problem that must be solved in the development of hot-pressed sintered diamond bead wire saws is;
(1). The design of the beaded carcass, including how to improve the holding force of the metal bond to the diamond and the bond strength between the carcass and the substrate;
(2). Bead manufacturing process, including bead cold pressing, hot pressing and corresponding mold design;
(3). Bead fixing materials and fixing technology. Among these three technologies, carcass formulation design and manufacturing processes are particularly important.
In order to solve the above problems, Taiwan China Grinding Wheel Company (KINIK) has developed a brazed diamond wire saw bead. The diamond on the bead is firmly held on the substrate by brazing, which allows the diamond particles to be evenly distributed. Each diamond can be cut efficiently, reducing the amount of diamond used, avoiding waste, and keeping the chips unobstructed. Practice has shown that the cutting efficiency of DicGrid brazed diamond bead is 4 times that of ordinary diamond bead.
Brazing and plating to make diamond tools:
The conventional plating process and the brazing process are equally specialized in the manufacture of single-layer diamond tools, and the advantages of the two processes can be expected to predict the prospects of their respective applications.
Dimensional Accuracy: Both electroplating (external plating) and brazing processes are based on a steel substrate. Each of them uses a different process to coat a layer of diamond on the steel substrate. Lin Zengdong believes that the diamond coating accuracy is similar, but for larger tools, the plating process is more precise than the brazing process. The reason is that the brazing process inevitably undergoes high-temperature heating (such as 800-1000 ° C), so that the steel matrix undergoes micro-deformation during thermal expansion and contraction, which is enough to affect the dimensional accuracy of the tool.
Grinding efficiency: The edge of the brazed diamond tool can be 2/3 of the diamond height, so the grinding efficiency is high, and it is good for scouring the grinding debris. The surface abrasive grains are not easy to lose grinding ability due to clogging.
Arrangement of diamond particles: electroplating a single layer of diamond to sand on the sand, the diamonds are arranged in a dense and disordered state. Brazing diamond particles can be arranged in an orderly manner, and the meteorite can be dilute and dense. It not only saves diamond, but also adapts to different grinding or other use requirements.
Diamond tool life: Brazing is the metallurgical combination of diamond particles and brazing alloy, that is, it is firmly welded, while the diamond particles in the electroplated diamond tool are only embedded by electroplating metal deposition, there is no metallurgical bond between the two, when the diamond wear exceeds the maximum The cross section must be detached, so the life of the brazed diamond tool is higher.
Effect on diamond performance: Diamond in brazed diamond tools must withstand high temperatures, albeit for a short period of time. However, it is enough to reduce the strength of the combined diamond, so it is necessary to select a diamond with good thermal stability and a brazing alloy that does not react strongly with the surface of the diamond. If the heating time is long, or the material is improperly selected, it will cause damage to the diamond surface, and some may even destroy the adhesion between the two.
Production cycle: Due to the deposition and thickening of the electroplated layer, it is generally carried out at a speed of 5-1-um/h, which determines that the electroplated diamond tool has a long production cycle; the brazed diamond tool is highly efficient, and its speed depends on The method of heating, the method is correct, can be completed in about ten minutes, and has nothing to do with the thickness of the selected diamond particles.
Manufacturing cost brazing method diamond concentration can be controlled. Can be dense and dense, can save diamond, the amount of brazing alloy can also be controlled.
The shape of the carburized diamond bead has a convex shape; the shape of the sintered diamond bead has a gentle shape; and the brazed diamond bead is wetted by the brazing. Its carcass shape is concave. Due to the different shape of the carcass, the height of the diamond-shaped edge of the ordinary bead is limited to 1/3 of the height of the abrasive grain: the height of the blade of the brazed bead can reach 2/3. Ordinary gold-made diamond beads usually contain only 0.5 gallon diamond; DiaGrid brazed diamond beads contain only Ol carat diamond. Although the diamond content is small, each diamond can work effectively, not only cost reduction, but also cutting. Improved performance, when sawing granite and marble, its life is similar to the normal type. When making brazed diamond beads, it is important to use high-strength, stable-quality diamonds such as DeAlers' SDAl00+ (grain size 40/50). DiaGrid Brazed Diamond Beads have been tested extensively in the United States, Germany, Italy and Taiwan for satisfactory cutting results.
The minimum diameter of ordinary bead is about 8mm, while the minimum diameter of DiaGrid brazed bead is 6mm. This bead is currently widely used in the world to process complex shapes of stone products [1].
As the carrier of the bead, the wire rope has a great influence on the cutting performance of the wire saw. If the life of the wire rope is short and the rope is broken frequently, the cutting performance of the bead can not be reflected. The study found that to improve the service life of steel wire ropes, the fatigue strength of steel wire ropes should be improved. Among all the mechanical properties of steel wire ropes, the most critical indicator is the fatigue strength of steel wire ropes. For example, a wire saw with a diameter of 8.5 mm has a wire saw length of 14.8 m and a cutting line speed of 30 m/s. Each time the wire saw rotates one turn, it is straightened by bending, and is alternately cycled twice by straight bending. The use time of a wire saw is about 500-1000h (depending on the width of the cutting object), at least 3.8 million cycles, and the straightening cycle is more than 7 million times. Moreover, when the wire saw is used, high-frequency vibration occurs due to the machine running unevenly. Therefore, the wire rope must have a high fatigue strength to meet the requirements of the wire saw.
Bead fixing technology, common bead fixing methods are spring fixing, plastic or rubber fixing, spring + plastic or rubber composite fixing. Compared with the spring fixing method, plastic or rubber fixing has the following two advantages:
(1) Plastic or rubber wraps the wire rope to prevent the cooling water carrying the rock powder from corroding and wearing the wire rope;
(2). The bead is reliably fixed on the wire rope to prevent the bead from rotating and striking, so that the hole in the bead base cannot wear the wire rope.
Therefore, cutting of strong abrasive substances such as granite and concrete is carried out by means of plastic or rubber fixing. The spring + plastic or rubber composite fixing method can more reliably fix the bead to the wire rope, but the manufacturing cost is high.
The diamond wire saw cuts thicker plates, is much thicker than the circular saw, and cuts much faster than the saw. Unlike ordinary tools, it can be sawed directly on site, while common tools have to be sawed in the factory. Practice has shown that when multiple sets of wire saws cut granite, the efficiency is higher than that of the row saw, which can be cut straight or curved, and the stone can be cut into more complicated shapes.
Because the wire saw has the above characteristics. Therefore, the application in the field of right-hand processing is on the rise. Diamond wire saws account for almost 10% of the world's diamond sawing products and are expected to grow rapidly in the future.
In recent years, diamond bead wire saws and diamond band saws have been fully exploited in marble mines. With the promotion of marble sawing mining technology and the further understanding of diamond bead wire saws, there is reason to believe that in the near future Diamond bead wire saws will be widely used in China's marble mining, making China's mining technology reach the world's advanced level.
In order to improve the production efficiency and processing quality of diamond wire saws and reduce costs, it is crucial to select reasonable parameters. To this end, Liu Baochang et al [2], based on theoretical analysis and experiments, studied the sawing trajectory and sawing mechanism of diamond wire saws and concluded the following:
(1) The sawing curve of the diamond wire saw is approximately a round involute, and the tension of the saw rope and the pressure applied to the stone by the unit length of the saw rope determine the shape of the involute;
(2). The wire rope saw has a high cutting speed. During the sawing process, the pressure of the single-grain diamond installation on the stone is very small, which is not enough to cause the stone to be broken. The main way of breaking the rock is Hertzian Fracture. The sawing is realized by high-speed grinding, so the chip size is small;
(3). According to the crushing mechanism of the diamond wire saw, the sawing rope should be properly controlled during the sawing to ensure a certain line speed of the sawing rope, and the diamond and the carcass with good wear resistance are selected to ensure good cooling. To improve the sawing speed and extend the life of the rope.
The diamond wire saw cuts the wreck. On December 14, 2002, the Tricolor cargo ship was on its way from the port of ZeebrUgge to South-ampton, due to heavy fog, and a container to Germany for the port of Kariba. The cargo ships collided. The Tricolor cargo ship was equipped with 3,000 cars (Audi, BMW, Volvo and Sic Bo), cranes and bulldozers, and sank for half an hour after the collision. After the accident. The authorities immediately made the decision to fight the Tricolor wreck. The Tricolor is 190m long and 32m wide, and 13 cargo holds have a weight of 27,000 tons. Snoring commissioned the Dutch company SMITSALVAGEB.V, because the company has achieved brilliant results in the war against the Kursk barge in Russia. In order to fight the cargo ship, this multinational group conducted a serious investigation and decided to use a diamond wire saw technology to saw its wreck into small pieces of 3,000 tons, and then transport them one by one to the port of Zeebrugge for treatment. Obviously this is diamond. The wire saw has made a big step forward in the technology of wrecking. [3]
Diamond bead wire saw is a tool for stone recovery and stone processing using flexible knives, especially in granite mining. Compared with traditional methods such as flame cutting and blasting, the shape of the stone material recovered is regular and neat, eliminating the need for a diamond bead. Subsequent block material shaping process has greatly improved the yield rate, and has low energy consumption, low vibration, low noise, no dust, good environmental friendliness and superiority in the production process.
Due to the high hardness of the granite, the loss on the bead is still large during the recovery process. In order to solve the above problems, Zhang Jinsheng et al. used the diamond bead wire saw for the beading wear performance and sawing speed of the Shidao red granite mining. The relationship between process parameters such as pre-tightening force of beaded wire saws was studied and pointed out:
(1). Diamond bead wire saw The processing mechanism of granite mining is mainly grinding and sliding. The speed of diamond bead wire sawing wire is high. The pressure of diamond single blade in sawing is small. The wear form of diamond particles is mainly abrasive grain. Wear, partial crushing, under certain processing conditions, there is an optimal sawing line speed, which minimizes the wear of the bead rope and the highest sawing rate. For the Shidaohong granite ore body, the optimum recovery speed is within the range of 2 lm/s to 23 m/s when the pre-tightening force is about 1800N;
(2). In a certain working speed range, the greater the pre-tightening force of the diamond bead rope, the greater the sawing force of the bead rope, the higher the efficiency, and the lower the wear resistance of the bead rope. The recovery efficiency of the integrated diamond bead wire saw and the wear resistance of the bead wire saw, the reasonable pre-tightening force of the stone island red granite is 1600N-1800N;
(3). Diamond bead wire saw is used for mining granite. It has safe operation, low noise, regular stone cutting, small slit and good environmental friendliness. The overall economic and social benefits are significant, and the application prospects are broad [6].
The research on wire saws started late in China, but in recent years it has developed very fast. Because of its structural rigidity, it has excellent performance. The processing method has the advantages of energy saving and environmental protection, and will expand its application range. Reports on the production of wire saws are rarely seen at home and abroad. According to some literature [7], the annual annual consumption is about 1.5 million meters and the value is 50 million US dollars. The annual value of domestic wire saws has exceeded 20 million yuan; and it is still developing at a high speed. All kinds of positive factors have determined that China's wire saw has a bright future. These factors include macro factors, such as the rapid development of the economy in the country, the emphasis on environmental protection, and industry factors. Through the joint efforts of the whole industry, China's synthetic diamond is the world's largest producer of diamonds, diamond single crystal. Production and some traditional tools such as cutter heads and grinding wheels are very thin, and people must look for high value-added products. The development of wire saws is relatively lagging due to its high technical difficulty. In recent years, domestic manufacturers have maintained good benefits due to the small number of manufacturers, and have good development prospects. The transfer of industry will greatly promote the development of wire saws.
The emergence of more than 60 multi-rope wire saws has brought a good opportunity for the development of wire saws, making it possible to replace traditional sand saws for sawing large plates; the rapid development of digital control technology, the increase of special-shaped stone, All of them bring good opportunities for the development of wire saws. At present, the smallest beaded rope in foreign countries is 3mm. It is said that the Guilin Institute of Geology and Geology completed the development of a lOmm sintered injection-type wire saw in 2000. Its performance has reached 80%-90% of the advanced level in foreign countries, and it has a price advantage; Successful on 8mm. The two-mm gap took a full three years. These technological breakthroughs will definitely lead to the accelerated development of wire saws [8].
At present, China's construction industry is developing at a high speed, especially in urban demolition and reconstruction. The application market of wire saws in this field is very broad. Wire saws are used in the construction field. Foreign countries generally use brazed injection molding. In many cases, dry-cut processing is used. Its huge market potential is worthy of efforts by the industry.
At present, the hard stone slabs such as sawn granite are sand saws, which are polluted, low in efficiency, and produce a large amount of waste in sawing; the emergence of multi-rope wire saws makes the bead wire saws competitive in this field. It has greatly improved, and has the advantages of high processing efficiency, small floor space, low energy consumption and less waste. Although the processing cost is about 20% higher than that of sand saws, due to the continuous development of wire saw sawing technology, its cost has been declining. Together with the advantages of energy saving and environmental protection, it is believed that it will replace sand saws and occupy hard stone in the near future. Large plate processing is a huge market.
Wire saws are a must-have tool for mining in Western countries. In China, most of the owners engaged in the exploitation of blocks are small and medium-sized enterprises, and the rough mining method is impossible to equip expensive wire saw mining equipment, resulting in a large amount of stone resources, along with the country’s resources and environment. The importance of this: With the accumulation of relevant enterprise technology and capital: the advanced mining tools of wire saws will be accepted by enterprises and greatly improve the level of this technical field in China.
Wire saws are used in a wide range of applications, and the working environment varies widely. It is required that the wire saws must be made with a strong target to produce wire saws with different performances to meet different requirements.
The high level of foreign wire saws comes from its technological leadership in all aspects. High-quality, special-purpose alloy powder, advanced diamond granulation technology and plating technology, mature high-temperature brazing technology, etc. are all important conditions for its technical success. At home, most of these technologies are still in the research stage. A successful product requires a lot of successful related technologies and product support; on the contrary, a good product can bring huge opportunities to many related products and technologies. China's wire saw manufacturers should cooperate with relevant industries to develop together; similarly, people of insight in relevant industries should seize the development opportunity of wire saws, improve their technological level, and realize the replacement of foreign technology and products.
At present, the use of domestic diamond wire saws is basically limited to the profile processing of stone, and other fields are rarely involved. From the perspective of China's big environment, the economy has been developing at a high speed for many years, and the changes in the appearance of the city are changing with each passing day. These have determined that diamond wire saws are promising in many aspects such as construction and demolition. People of insight in the industry should speed up the development of brazed wire saws or design such a demanding beaded rope to quickly occupy this huge market.
In foreign countries, the emergence of more than 60 multi-rope wire saws, the trend of wire saws instead of sand saws for sawing granite slabs is becoming more and more obvious; with the breakthrough of wire saw equipment, it will bring a huge market; Some types of beaded ropes are similar in quality to similar foreign products, and have certain advantages in price, which can be completely entered into foreign markets.
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