Abstract
Predicting the wear rate of diamond beads in the diamond wire sawing process is one of the most important factors in the optimized design and cost estimation of quarrying. This paper aims to predict the wear rate of diamond beads as one of the principal performance criteria in dimension stone quarrying. Saw operating parameters and mechanical and physical properties of rock are the most effective factors on diamond bead wear. In the same working conditions (at constant operating parameters), the wear rate of diamond wire saw is strongly affected by the production rate, and the characteristics of rock. In this study, the uniaxial compressive strength, Schmiazek abrasivity factor, Mohs hardness, and Young’s modulus were selected as the main physical and mechanical properties of rock. The 11 types of igneous rocks were cut in the laboratory using a diamond wire saw and a fully instrumented cutting platform. During the cutting process, the wear rate of diamond beads were determined after each cutting test. The wear rate of diamond bead and rock characteristics were evaluated using simple and multiple curvilinear regression analysis, and prediction models were developed. The developed models were validated by considering the t-test, F-test, correlation coefficient and the plots of predicted versus actual values. The results indicated that the wear rate of diamond beads can be reliably predicted using the developed model.
Similar content being viewed by others
References
Agus M, Bortolussi A, Careddu N, Ciccu R, Grosso B, Massacci G (2005) Influence of stone properties on diamond wire performance. In: Proceedings of the 1st International Congress on Dimension Stones, Guarapari
Almasi SN, Bagherpour R, Mikaeil R, Khademian A (2015) Influence of cutting wire tension on travertine cutting rate. In: Proceedings of 24th International Mining Congress and Exhibition of Turkey, pp 1096–1102
Ataei M, Mikaeil R, Hoseinie SH, Hosseini SM (2012) Fuzzy analytical hierarchy process approach for ranking the sawability of carbonate rock. Int J Rock Mech Min Sci 50:83–93
Bagherpour R, Khademian A, Almasi SN, Aalaei M (2014) Optimum cutting wire assembly situation in dimension stone quarries. J Min Metall A: Mining 50:1–8
Beste U, Jacobson S (2003) Micro scale hardness distribution of rock types related to rock drill wear. Wear 254:1147–1154
Brown ET (1981) Rock characterization, testing & monitoring: ISRM suggested methods. International Society for Rock Mechanics, Oxford
Cai O, Careddu N, Mereu M, Mulas I (2007) The influence of operating parameters on the total productivity of diamond wire in cutting granite. Ind Diamond Rev 67:3
Cassapi V, Phil M (1987) Application of rock hardness and abrasive index in rock excavating equipment selection. University of Nottingham
Chatterjee TK, Chatterjee R, Singh S (2005) Classification of black decorative stones from Warangal District, Andhra Pradesh, India. Bull Eng Geol Environ 64:167–173
Fener M, Kahraman S, Ozder M (2007) Performance prediction of circular diamond saws from mechanical rock properties in cutting carbonate rocks. Rock Mech Rock Eng 40:505–517
Gelfusa G, Turchetta S (2014) Cutting force and tool wear of single diamond-coated bead. Int J Adv Manuf Technol 72:1063–1072
Ghaysari N, Ataei M, Sereshki F, Mikaiel R (2012) Prediction of performance of diamond wire saw with respect to texture characteristics of rock/Prognozowanie Wydajności Pracy Strunowej Piły Diamentowej W Odniesieniu do Charakterystyki Tekstury Skał. Arch Min Sci 57:887–900
Hardin CW, Qu J, Shih AJ (2004) Fixed abrasive diamond wire saw slicing of single-crystal silicon carbide wafers. Mater Manuf Process 19:355–367
Hasanpour R, Ozcelik Y, Yilmazkaya E, Sohrabian B (2016) DEM modeling of a monowire cutting system. Arab J Geosci 9:739
Jain S, Rathore S (2011) Prediction of cutting performance of diamond wire saw machine in quarrying of marble: a neural network approach. Rock Mech Rock Eng 44:367–371
Kahraman S, Fener M, Gunaydin O (2004) Predicting the sawability of carbonate rocks using multiple curvilinear regression analysis. Int J Rock Mech Min Sci 41:1123–1131
Karakurt I (2014) Specific energy optimization in sawing of rocks using Taguchi approach. J Cent South Univ 21:365–372
Kellough PH (1985) Statistical package for the social sciences bibliography: Selected SPSS manuals and research articles using SPSS. Vance Bibliographies, Monticello, IL
Khademian A, Bagherpour R, Almasi SN, Alaei M (2015) Optimum distance between cutting machine and working face in travertine exploitation with diamond wire cutting method. In: Proceedings of 24th International Mining Congress and Exhibition of Turkey, pp 1103–1110
Konstanty J (2002) Theoretical analysis of stone sawing with diamonds. J Mater Process Technol 123:146–154
Korre A, Durucan S (2000) The effects of granite microstructure on the sawing performance of diamond wires. Int J Min Reclam Env 14:87–102
Liao Y, Luo S (1992) Wear characteristics of sintered diamond composite during circular sawing. Wear 157:325–337
Liedke T, Kuna M (2013) Discrete element simulation of micromechanical removal processes during wire sawing. Wear 304:77–82
Mikaeil R, Ozcelik Y, Yousefi R, Ataei M, Mehdi Hosseini S (2013) Ranking the sawability of ornamental stone using fuzzy Delphi and multi-criteria decision-making techniques. Int J Rock Mech Min Sci 58:118–126
Mikaeil R, Ozcelik Y, Ataei M, Shaffiee Haghshenas S (2016) Application of harmony search algorithm to evaluate the performance of diamond wire saw. J Min Environ. doi:10.22044/jme.2016.723
Montgomery DC (2013) Design and analysis of experiments, eighth edn. Wiley, New York
Özçelik Y (2003) Multivariate statistical analysis of the wear on diamond beads in the cutting of andesitic rocks. In: Key engineering materials. Trans Tech, Zurich, pp 118–130
Özçelik Y (2005) Optimum working conditions of diamond wire cutting machines in the marble industry. Ind Diamond Rev 65:58–64
Özçelik Y, Bayram F (2004) Optical investigations of bead wear in diamond wire cutting. Ind Diamond Rev 64:60–65
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 48:626–636
Özçelik Y, Kulaksız S, Çetin M (2002) Assessment of the wear of diamond beads in the cutting of different rock types by the ridge regression. J Mater Process Technol 127:392–400
Ozcelik Y, Polat E, Bayram F, Ay A (2004) Investigation of the effects of textural properties on marble cutting with diamond wire. Int J Rock Mech Min Sci 41:228–234
Ribeiro RP, Paraguassú AB, Rodrigues JE (2007) Sawing of blocks of siliceous dimension stone: influence of texture and mineralogy. Bull Eng Geol Environ 66:101–107
Ribeiro RP, Paraguassú AB, STF M (2011) Factors affecting slab surface roughness of siliceous dimension stones. Bull Eng Geol Environ 70:625–631
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
Tönshoff H, Warnecke G (1982) Research on stone sawing advances in Ultrahard. Mater Appl Technol 1:36–49
Turchetta S, Polini W, Gelfusa G, Venafro E (2014) A new sawing machine by diamond wire. Int J Adv Manuf Technol 70:73–78
Yilmazkaya E, Ozcelik Y (2015) Development of cuttability chart for a marble cutting with monowire cutting machine. In: International Conference on Stone and Concrete Machining (ICSCM), pp 73–85
Yilmazkaya E, Özçelik Y (2015) Development of cuttability chart for a limestone cutting with monowire cutting machine. In: 49th US Rock Mechanics/Geomechanics Symposium. American Rock Mechanics Association
Yilmazkaya E, Ozcelik Y (2016) The effects of operational parameters on a mono-wire cutting system: efficiency in marble processing. Rock Mech Rock Eng 49:523–539
Zhang JS, Wang Z (2004) Technical parameters and wear resistibility of diamond wire-saw in granite cutting. In: Key engineering materials. Trans Tech, Zurich, pp 122–126
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Najmedin Almasi, S., Bagherpour, R., Mikaeil, R. et al. Analysis of bead wear in diamond wire sawing considering the rock properties and production rate. Bull Eng Geol Environ 76, 1593–1607 (2017). https://doi.org/10.1007/s10064-017-1057-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10064-017-1057-9