Advertisement

Determining the optimum cutting direction in granite quarries through experimental studies: a case study of a granite quarry

  • Reza YarahmadiEmail author
  • Raheb Bagherpour
  • Amir Khademian
  • Luis M.O. Sousa
  • Seied Najmedin Almasi
  • Mahin Mansouri Esfahani
Original Paper

Abstract

Optimization of cutting operations in quarrying and processing of building stones leads to certain reductions in operational costs. Despite the developments of cutting technology and employment of more efficient cutting machines, there is still a need to optimize a series of operational parameters; the cutting direction is one of them. In order to optimize the cutting direction parameter in cutting processes, an experimental study was designed in a granite quarry. For this purpose, 12 granite samples along 12 different directions with 15° intervals were cut by a special laboratory wire cutting machine. The obtained cutting rate showed that different cutting directions demonstrate very diverse cutting rates. A significant difference of 43% was found between the highest and lowest cutting rates. Also, the optimal cutting direction was found to be 185° relative to the geographical north. Furthermore, microscopic studies on petrographic thin sections were performed to analyze the cutting rate results. Analysis showed that the rock’s equivalent hardness was not correlated to the cutting rate, while there is a possible direct relationship between the quartz content and the cutting rate. Besides, results confirmed the currently identified splitting planes of the quarry and showed a potential relationship with the main fault system of the area.

Keywords

Rock heterogeneity Cutting rate Granite Building stones Quarry 

References

  1. Altindag R (2010) Assessment of some brittleness indexes in rock-drilling efficiency. Rock Mech Rock Eng 43:361–370CrossRefGoogle Scholar
  2. Altindag R, Guney A (2010) Predicting the relationships between brittleness and mechanical properties (UCS, TS and SH) of rocks. Sci Res Essays 5:2107–2118Google Scholar
  3. Amaral PM, Fernandes JC, Rosa LG (2009) Wear mechanisms in materials with granitic textures—applicability of a lateral crack system model. Wear 266:753–764.  https://doi.org/10.1016/j.wear.2008.08.018 CrossRefGoogle Scholar
  4. Aslantas K, Özbek O, Ucun I, Büyüksağ ş İS (2009) Investigation of the effect of axial cutting force on circular diamond sawblade used in marble cutting process. Mater Manuf Process 24:1423-1430Google Scholar
  5. Bagherpour R, Khademian A, Almasi S, Aalaei M (2014) Optimum cutting wire assembly in dimension stone quarries. J Min Metall A: Mining 50:1–8CrossRefGoogle Scholar
  6. Bandini A, Berry P (2013) Influence of marble’s texture on its mechanical behavior. Rock Mech Rock Eng 46:785–799CrossRefGoogle Scholar
  7. Bandini A, Berry P, Bemporad E, Sebastiani M (2012) Effects of intra-crystalline microcracks on the mechanical behavior of a marble under indentation. Int J Rock Mech Min Sci 54:47–55CrossRefGoogle Scholar
  8. Benavente D, Cultrone G, Gómez-Heras M (2008) The combined influence of mineralogical, hygric and thermal properties on the durability of porous building stones. Eur J Mineral 20:673–685CrossRefGoogle Scholar
  9. Berberian F (1981) Petrogenesis of Iranian plutons: a study of the Natanz and Bazman intrusive complexes. University of CambridgeGoogle Scholar
  10. Bilim N (2012) Optimum cutting speed of block-cutting machines in natural stones for energy saving. J Cent South Univ 19:1234–1239CrossRefGoogle Scholar
  11. Burton CL, Waltham AC, McLaren SJ (2001) Strength variation in young reef limestones. Géotechnique 51:887–889.  https://doi.org/10.1680/geot.2001.51.10.887 CrossRefGoogle Scholar
  12. Buyuksagis IS (2007) Effect of cutting mode on the sawability of granites using segmented circular diamond sawblade. J Mater Process Technol 183:399–406.  https://doi.org/10.1016/j.jmatprotec.2006.10.034 CrossRefGoogle Scholar
  13. Buyuksagis IS, Goktan RM (2005) Investigation of marble machining performance using an instrumented block-cutter. J Mater Process Technol 169:258–262.  https://doi.org/10.1016/j.jmatprotec.2005.03.014 CrossRefGoogle Scholar
  14. Copur H (2010) Linear stone cutting tests with chisel tools for identification of cutting principles and predicting performance of chain saw machines. Int J Rock Mech Min Sci 47:104–120.  https://doi.org/10.1016/j.ijrmms.2009.09.006 CrossRefGoogle Scholar
  15. Copur H, Balci C, Tumac D, Bilgin N (2011) Field and laboratory studies on natural stones leading to empirical performance prediction of chain saw machines. Int J Rock Mech Min Sci 48:269–282.  https://doi.org/10.1016/j.ijrmms.2010.11.011 CrossRefGoogle Scholar
  16. Ersoy A, Atıcı U (2004) Performance characteristics of circular diamond saws in cutting different types of rocks. Diam Relat Mater 13:22–37.  https://doi.org/10.1016/j.diamond.2003.08.016 CrossRefGoogle Scholar
  17. Ersoy A, Atici U (2005) Specific energy prediction for circular diamond saw in cutting different types of rocks using multivariable linear regression analysis. J Min Sci 41:240–260.  https://doi.org/10.1007/s10913-005-0089-x CrossRefGoogle Scholar
  18. Ersoy A, Atici U (2007) Correlation of P and S-waves with cutting specific energy and dominant properties of volcanic and carbonate rocks. Rock Mech Rock Eng 40:491–504.  https://doi.org/10.1007/s00603-006-0111-x CrossRefGoogle Scholar
  19. Fener M, Kahraman S, Ozder MO (2007) Performance prediction of circular diamond saws from mechanical rock properties in cutting carbonate rocks. Rock Mech Rock Eng 40:505–517.  https://doi.org/10.1007/s00603-006-0110-y CrossRefGoogle Scholar
  20. Freire-Lista DM, Fort R (2017) Exfoliation microcracks in building granite, implications for anisotropy. Eng Geol 220:85–93.  https://doi.org/10.1016/j.enggeo.2017.01.027 CrossRefGoogle Scholar
  21. Gunes Yılmaz N (2013) Process efficiency comparison of a sandwich-core sawblade and a conventional sawblade used in stone-machining. J Clean Prod 47:26–31.  https://doi.org/10.1016/j.jclepro.2013.01.042 CrossRefGoogle Scholar
  22. Gunes Yılmaz N, Goktan RM, Kibici Y (2011) An investigation of the petrographic and physico-mechanical properties of true granites influencing diamond tool wear performance, and development of a new wear index. Wear 271:960–969.  https://doi.org/10.1016/j.wear.2011.04.007 CrossRefGoogle Scholar
  23. Güney A (2011) Performance prediction of large-diameter circular saws based on surface hardness tests for Mugla (Turkey) marbles. Rock Mech Rock Eng 44:357–366CrossRefGoogle Scholar
  24. Hekimoglu OZ (2014) Studies on increasing the performance of chain saw machines for mechanical excavation of marbles and natural stones. Int J Rock Mech Min Sci 72:230–241CrossRefGoogle Scholar
  25. Honarmand M, Moayyed M, Jahangiri A, Ahmadian J, Bahadoran N (2010) The study of geochemical characteristics of Natanz plutonic complex, north of Isfahan. Petrology 1:65–88Google Scholar
  26. Inc IT (2015) Informer Technologies Inc TSView. http://tsview.software.informer.com/
  27. Kahraman S, Gunaydin O (2008) Indentation hardness test to estimate the sawability of carbonate rocks. Bull Eng Geol Environ 67:507–511.  https://doi.org/10.1007/s10064-008-0162-1 CrossRefGoogle Scholar
  28. Karakurt I (2014) Application of Taguchi method for cutting force optimization in rock sawing by circular diamond sawblades. Sadhana 39:1055–1070CrossRefGoogle Scholar
  29. Khanlari GR, Heidari M, Sepahi A, Fereidooni D (2013) Determination of geotechnical properties of anisotropic rocks using some index tests. Geotech Test J 37:1–13Google Scholar
  30. King H (2015) http://geology.com/minerals/mohs-hardness-scale.shtml, Date Access: 2015. Mohs Hardness Scale
  31. Montgomery DC (2017) Design and analysis of experiments. John Wiley & Sons, HobokenGoogle Scholar
  32. Özçelik Y (2005) Optimum working conditions of diamond wire cutting machines in the marble industry. Ind Diamond Rev 1:58–64Google Scholar
  33. Ozcelik Y, Yilmazkaya E (2011) The effect of the rock anisotropy on the efficiency of diamond wire cutting machines. Int J Rock Mech Min Sci 48:626–636CrossRefGoogle Scholar
  34. Pershin GD, Ulyakov MS (2014) Analysis of the effect of wire saw operation mode on stone cutting cost. J Min Sci 50:310–318.  https://doi.org/10.1134/S1062739114020148 CrossRefGoogle Scholar
  35. Přikryl R (2001) Some microstructural aspects of strength variation in rocks. Int J Rock Mech Min Sci 38:671–682.  https://doi.org/10.1016/S1365-1609 (01)00031-4 CrossRefGoogle Scholar
  36. Sánchez Delgado N, Rodríguez-Rey A, Suárez del Río LM, Díez Sarriá I, Calleja L, Ruiz de Argandoña VG (2005) The influence of rock microhardness on the sawability of pink Porrino granite (Spain). Int J Rock Mech Min Sci 42:161–166.  https://doi.org/10.1016/j.ijrmms.2004.08.010 CrossRefGoogle Scholar
  37. Sengun N, Altindag R (2013) Prediction of specific energy of carbonate rock in industrial stones cutting process. Arab J Geosci 6:1183–1190CrossRefGoogle Scholar
  38. Sousa LM (2013) The influence of the characteristics of quartz and mineral deterioration on the strength of granitic dimensional stones. Environ Earth Sci 69:1333–1346CrossRefGoogle Scholar
  39. Sousa LM (2014) Petrophysical properties and durability of granites employed as building stone: a comprehensive evaluation. Bull Eng Geol Environ 73:569–588CrossRefGoogle Scholar
  40. Sousa L, Barabasch J, Stein K-J, Siegesmund S (2017) Characterization and quality assessment of granitic building stone deposits: a case study of two different Portuguese granites. Eng Geol 221:29–40.  https://doi.org/10.1016/j.enggeo.2017.01.030 CrossRefGoogle Scholar
  41. Sun L, Pan J, Lin C (2002) A new approach to improve the performance of diamond sawblades. Mater Lett 57:1010–1014CrossRefGoogle Scholar
  42. Tiryaki B, Dikmen AC (2006) Effects of rock properties on specific cutting energy in linear cutting of sandstones by picks. Rock Mech Rock Eng 39:89–120.  https://doi.org/10.1007/s00603-005-0062-7 CrossRefGoogle Scholar
  43. Turchetta S (2012) Cutting force and diamond tool wear in stone machining the international. J Adv Manuf Technol 61:441–448.  https://doi.org/10.1007/s00170-011-3717-4 CrossRefGoogle Scholar
  44. Tutmez B, Kahraman S, Gunaydin O (2007) Multifactorial fuzzy approach to the sawability classification of building stones. Constr Build Mater 21:1672–1679CrossRefGoogle Scholar
  45. Vázquez P, Alonso FJ, Carrizo L, Molina E, Cultrone G, Blanco M, Zamora I (2013) Evaluation of the petrophysical properties of sedimentary building stones in order to establish quality criteria. Constr Build Mater 41:868–878.  https://doi.org/10.1016/j.conbuildmat. 2012.12.026 CrossRefGoogle Scholar
  46. Wang JK, Ai X, Xu GJ, Zhang JS (2010). Experimental study for the cutting forces during sawing granite with diamond circular saw blades. In: Key Engineering Materials, Trans Tech Publ, pp 86-89Google Scholar
  47. Webb S, Jackson W (1998) Analysis of blade forces and wear in diamond stone cutting. J Manuf Sci Eng 120:84–92CrossRefGoogle Scholar
  48. Wei X, Wang CY, Zhou ZH (2003) Study on the fuzzy ranking of granite sawability. J Mater Process Technol 139:277–280.  https://doi.org/10.1016/S0924-0136(03)00235-8 CrossRefGoogle Scholar
  49. Xie J, Tamaki J (2007) Parameterization of micro-hardness distribution in granite related to abrasive machining performance. J Mater Process Technol 186:253–258.  https://doi.org/10.1016/j.jmatprotec.2006.12.041 CrossRefGoogle Scholar
  50. Yarahmadi R, Bagherpour R, Sousa LM, Taherian S-G (2015) How to determine the appropriate methods to identify the geometry of in situ rock blocks in dimension stones. Environ Earth Sci 74:6779–6790CrossRefGoogle Scholar
  51. Yarahmadi R, Bagherpour R, Tabaei M, Sousa LMO (2017) Investigation of intact rock geomechanical parameters' effects on commercial blocks’ productivity within stone reserves: a case history of some quarries in Isfahan, Iran. J Afr Earth Sci 134:383–388.  https://doi.org/10.1016/j.jafrearsci.2017.07.013 CrossRefGoogle Scholar
  52. Yılmaz NG (2011) Abrasivity assessment of granitic building stones in relation to diamond tool wear rate using mineralogy-based rock hardness indexes. Rock Mech Rock Eng 44:725–733CrossRefGoogle Scholar
  53. Yilmaz NG (2015) Size analysis of the chips generated during abrasive machining of granite in relation to productivity and efficiency parameters particulate science and technologyGoogle Scholar
  54. Yilmaz NG, Karaca Z, Goktan R, Akal C (2009) Relative brittleness characterization of some selected granitic building stones: influence of mineral grain size. Constr Build Mater 23:370–375CrossRefGoogle Scholar
  55. Yılmaz NG, Goktan RM, Kibici Y (2011) Relations between some quantitative petrographic characteristics and mechanical strength properties of granitic building stones. Int J Rock Mech Min Sci 48:506–513CrossRefGoogle Scholar
  56. Yilmaz NG, Göktan RM, Gaşan H, Çelik ON (2013) Particle size distribution and shape characterization of the chips produced during granite machining in relation to process forces and specific energy. Part Sci Technol 31:277–286CrossRefGoogle Scholar
  57. Yilmaz NG, Tumac D, Goktan RM (2015) Rock cuttability assessment using the concept of hybrid dynamic hardness (HDH). Bull Eng Geol Environ 74:1363–1374.  https://doi.org/10.1007/s10064-014-0692-7 CrossRefGoogle Scholar
  58. Yurdakul M (2015) Effect of cutting parameters on consumed power in industrial granite cutting processes performed with the multi-disc block cutter. Int J Rock Mech Min Sci 76:104–111.  https://doi.org/10.1016/j.ijrmms.2015.03.008 CrossRefGoogle Scholar
  59. Yurdakul M, Akdasˎ H (2012) Prediction of specific cutting energy for large diameter circular saws during natural stone cutting. Int J Rock Mech Min Sci 53:38–44.  https://doi.org/10.1016/j.ijrmms.2012.03.008 CrossRefGoogle Scholar
  60. Yurdakul M, Gopalakrishnan K, Akdas H (2014) Prediction of specific cutting energy in natural stone cutting processes using the neuro-fuzzy methodology. Int J Rock Mech Min Sci 67:127–135.  https://doi.org/10.1016/j.ijrmms.2014.01.015 CrossRefGoogle Scholar
  61. Zhang ZM, Xiao HW, Wang GZ, Zhang SZ, Zhang SQ (2013). Modeling and experimental study on cutting force of diamond circular saw in cutting granite using response surface methodology. In: Advanced Materials Research, Trans Tech Publ, pp 2191-2195Google Scholar

Copyright information

© Springer-Verlag GmbH Germany 2017

Authors and Affiliations

  1. 1.Department of Mining EngineeringIsfahan University of TechnologyIsfahanIran
  2. 2.Department of GeologyUniversity of Trás-os-Montes e Alto DouroVila RealPortugal

Personalised recommendations