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Rock Breakage and Tools Performance During Rock Processing by Multidiameter Combination Saw with Different Diameters

Abstract

To better understand the rock breakage mechanism and optimize tool performance during rock machining by multidiameter combination saw, the rock processing experiment using a multidiameter combination saw was carried out on the bridge saw to investigate the variation of load with diameter in the combination saw. Furthermore, in this study, the sawing forces, tools wear, and rock breakage in the processing rock were qualitatively analyzed and compared. The experimental investigations demonstrated that the maximum undeformed chip thickness, the load per diamond, and the load in the sawing arc zone all decrease with increasing diameters of the single saw in the combination saw. The sum of the vertical forces of the single saw is generally less than that of the combination saw under the same parameters because of the existence of the coupling effect between the single saws. Different failure mechanisms of particles in the worn segment of the tool with different diameters also operate in rock processing using a multidiameter combination saw. With increasing diameter of saw blade, the proportion of the whole and blunt diamond particles increases, and that of the macro-fractured and pulled-out crystals decreases. Moreover, the differences in the surface integrity are attributed to the variation in the maximum undeformed chip thickness on the saw blade with different diameters in the combination saw and the gully depth on the surface, and the surface roughness of rock decreases with increasing diameter of the single saw.

Highlights

  • The experiments for rock processing by a multidiameter combination saw are designed to investigate the sawing performance of multidiameter combination circular saw with different diameters.

  • Different failure mechanisms of particles in the worn segment of the tool with different diameters operate in rock processing using a multidiameter combination saw.

  • The differences in the surface integrity are attributed to the variation in the maximum undeformed chip thickness on the saw blade with different diameters in the combination saw.

  • Coupling effect between the single saws affects decomposition and generation of forces in the multidiameter saw.

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Abbreviations

\(h_{\max }\) :

Maximum undeformed chip thickness (um)

\(Q_{{\text{w}}}\) :

Material removal rate (mm2/s)

\({\text{v}}_{{\text{w}}}\) :

Feed speed (mm/s)

\(\theta_{g}\) :

Semi-included angle of the chip shapes of grain point, which was considered with a triangular section (rad)

\(a_{p}\) :

Sawing depth (mm)

\(\theta\) :

Angle of sawing zone (rad)

\(d_{s}\) :

Circular saw diameter (mm)

\({\text{v}}_{{\text{s}}}\) :

Linear velocity of circular saw (mm/s)

\(\omega\) :

Angular velocity of circular saw (rad/s)

\(C_{a} = C\eta \lambda {/}l_{s} B\) :

The active grain density, which is defined as the number of active grits per unit area of the circumference surface

\(C\) :

Number of effective abrasive particles on the surface of a single segment

\(\eta\) :

Specific value, which is the proportion of the actual abrasive particles involved in sawing to the number of effective abrasive particles

\(\lambda { = }l_{s} {/}l_{s} { + }l_{{\text{w}}}\) :

Specific value between the total length of diamond segments and the saw blade circumference

\(\alpha\) :

Angle of sawing arc zone (rad)

\(\beta\) :

Angle of the position of the resultant force (rad)

\(l_{c}\) :

Length of sawing arc zone (mm)

\(l_{s}\) :

Length of segment (mm)

\(l_{w}\) :

Length of slot (mm)

\(B\) :

Width of the segment (mm)

\(f_{t}\) :

The tangential load per diamond (N)

\(f_{n}\) :

The normal load per diamond (N)

\(F_{{\text{t}}}\) :

Sawing tangential force (N)

\(F_{n}\) :

Sawing normal force (N)

\(F_{z}\) :

Sawing vertical force (N)

\(F_{y}\) :

Sawing horizontal force (N)

\(F_{x}\) :

Sawing axial force (N)

\(i\) :

Number of circulars saw \(i\) = 1, 2, 3

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Acknowledegments

This work was supported by the Shandong Key Research and Development Project [2019GGX104022], the Scientific and Technological Innovation Project of Rizhao [2019CXZX1109] and Guangdong Basic and Applied Basic Research Foundation [2021A1515110177]. The authors are deeply grateful to Rizhao Hein Saw Co., Ltd., Huajian Stone Co., Ltd., and Meihua Stone Co., Ltd. for supporting this research by providing the circular sawing machine, the diamond tools and workpieces.

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Correspondence to Jinsheng Zhang or Heng Zhang.

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The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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Zhou, J., Wang, K., Zhang, J. et al. Rock Breakage and Tools Performance During Rock Processing by Multidiameter Combination Saw with Different Diameters. Rock Mech Rock Eng 55, 4459–4476 (2022). https://doi.org/10.1007/s00603-022-02824-9

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  • DOI: https://doi.org/10.1007/s00603-022-02824-9

Keywords

  • Multidiameter combination saw
  • Rock breakage
  • Forces
  • Wear
  • Diamond