Stone mined using diamond wire saw British DHProwse idea is put forward in 1968. The first practical machine by LuigMadrigali in October 1977 successfully developed in Italy. Within a few years time, the production of hundreds of Saw, Italy more than 200 quarries all promote the use of rope saw, therefore, Diamond Wire Saw first use in Italy, known as the "marble mining revolution." VERONA, Italy in the 1969-1970 fiscal year S.Ambrogio Stone Fair, first exhibited the beaded rope and processing equipment plating beaded belt. Since then, the great potential of the tool has been developed rapidly.

 

After two decades of research and development, not only widely used in diamond wire saw marble mining, but also for sandstone, granite and other hard rock separating cut; not only for open-pit mining, but also for narrow veins and underground explosions dangerous mining underground gold mine in South Africa; not only for special-shaped stone products processing, but also for the removal and repair buildings and reinforced concrete construction and road works.

 

Diamond Wire Saw creative use in quarrying and construction projects, making Diamond Wire Saw the stone from the quarry to the plant, from large cut to trim molding, sheet metal cutting into shaped products from the processing and construction Engineering more and more.

 

Diamond wire saw as diamond tools in the development of third-generation product, after 20 years of research and improvement, now widely used in various projects. This is mainly because it has the following advantages:

(1) The equipment is simple, easy to install, free space and spatial limitations, can be horizontal, vertical and diagonal direction cutting, sawing area of up to 200m2, good processing quality, stone, low loss, cutting speed, low noise vibration good small work environment, adaptability, can choose different specifications and sizes of diamond wire saw cutting equipment and working conditions based on the object.

(2) significantly increased the rate of stone mining blocks to protect the precious stone resources.

(3) process a variety of shapes shaped granite and marble products, its high added value, can significantly improve economic efficiency.

(4) can be mined large chunks of blocks, timber size increases, thereby increasing the advanced stone processing equipment specifications sheet, improve cutting efficiency and economic benefits.

(5) The diamond wire saw superiority, no doubt solve the low blocks of stone industry emerged, a shortage of large-sized plates, shaped products can not meet the requirements of domestic and international conflicts, which can produce a big boost. Rope saw positive development and promotion, is an important part of the development of China's stone industry.

 

Since the advent of diamond wire saw, wire saw manufacturing process is the process of innovation, but also continue to develop and expand rope saw the application process. Currently the world there are more than 2,000 mining marble wire saw, there are more than 1,000 mining granite wire saw, blocks of plastic and sheet metal saws Qiesheng saw increasing wire saw as many as 50-100 units. Discount for building repair and maintenance, traffic engineering alterations increasing use of wire saws. Studies have shown that diamond beads is still a major factor in diamond wire saw cutting costs and benefits. Therefore, at home and abroad around the beaded made a series of innovative manufacturing processes:

(1) forming a kind beaded plating, high temperature sintering and brazing multiple product types;

(2) KPV218, WPD20 cold press significantly improve production efficiency beaded cold, cold domestic manual process is also continuous improvement;

(3) beaded sintering technology continue to improve;

(4) injection molded or vulcanized rubber beads;

(5) Application of high temperature brazing obtained;

(6) the development of diamond wire saws to small diameter;

(7) by powder plastic "online" processing technology to produce small-diameter diamond wire saw;

(8) rope saw blade, Dr. Fritsch Company had launched SAMl50 rope saw blade machine, 10-50m long rope can be opened and saw blade.

 

Supplies nearly every part of our lives is very important. Depending on the specific purpose of housing construction, and to use a lot of different types of materials. Because these buildings need constant renovation and decoration, these materials need to use a linear cutting tool cutting and alterations. Sawing wire system is widely used in cutting metal, stone and concrete terms. In the scene, wire saws mechanical dimensions currently used is too large and difficult to operate. The reason is that its transmission components provided by the rated power is too big, and its design is too heavy, so the development of a special small wire saw cutting system is very necessary. To develop an advanced wire saw systems in order to meet market needs, the joint research of Europe's leading companies formed in the EC CRAFT project-based, not only for end users and research institutes wire saw, and there equipment and tool manufacturing companies are actively involved in the research project. Develop new machines main supplier CEDINA, production engineering and machine tools FerdinandKoller & Sohn Academy and the University of Hannover in close collaboration by the wire saw system. Cedima wire saw system suppliers to take a variety of new machine parts, especially high frequency motors make up the design and development. FerdinandKoBer & Shon factory responsible for manufacturing the new wire saw. Produced by HB Wire Saw Diamond Wire Saw plant. Robuco (Wire Saw user) in wire saw cutting aspects of its extensive knowledge and experience in the development and manufacture of the full support of the entire wire saw system.

 

For the development of new small and equipped with a diamond wire saw cutting beaded small size. These smaller sized beads impossible to use commonly used to cool, then hot pressing method of making such a production process has been fully automated. The new manufacturing method using a hot isostatic HIP method.

 

Because of the new wire saw diameter decreases, as the well-known toxic material cobalt reduction in the carcass. In small diameter wire saws, materials harmful to human health reduced by 75% cobalt, thereby reducing environmental pollution.

 

Using string saws and ordinary wire saw cutting reinforced concrete test results showed that the diameter of 11.5mm and 8.5mm common wire saws comparison, with a diameter of 6.5m (small) wire saw cutting, due to the feed pressure is relatively low, so the cutting force and energy consumption is much lower.

 

Compared with 11.5mm diameter rope saw, its cutting force and reduce energy consumption by 40%; compared with the diameter of 8.5mm wire saws, cutting power and reduce energy consumption by 30%.

 

Determination of different diameter wire sawing noise level showed that rope saw diameter decreases, reducing the noise level. Cutting speed also depends on the noise level, but its impact is not great. The main factor is the diameter of the wire saw. For d-11mm rope saw, its cutting speed Vc = 16.7m / s when, lm distant noise average 92dB (A). For medium-sized rope saw, sawing at the same speed, the noise dropped to 89dB (A). The use of smaller diameter wire saw, the noise is about 87dB (A). This means that the use of smaller diameter wire saw, decreased noise can be achieved 5dB (A).

 

From the test of the most important finding is that the use of smaller diameter wire saw will significantly reduce the feed pressure. Reduce by 25% the diameter of the wire saw will allow feed pressure reduced by more than 25%. Sawing process compared with the conventional wire saw operation, which saw the rope wear and skew are reduced to a minimum level.

 

In short, the current structure of wire saws saws used in construction sites is too large, easy to operate and move from the point of view, does not meet the ergonomic requirements. To do this requires a small and lightweight versatility Wire Saw Saw. The newly developed rope saw Saw a Master to complete all the installation and operation of the entire system, the various components of the machine for easy installation and removal, the weight of each component is not more than 25Kg. Thanks to the newly developed machine tool wire saw, will produce less waste, less noise and less pollution, so that the superiority of the wire saw can be more prominent.

 

Diamond Wire Saw initially only for the exploitation of natural stone, the first generation of diamond wire saw beads for plating type, and then develop a sintered. Diamond beaded full and nickel plating on the adhesive grip; sintered diamond beads are all dominated by metal binder (such as cobalt). The former contains a layer of diamond, which is a multi-layer gold cut stone. Electroplated diamond wire type in the initial stages of its cutting speed cutting faster, but will soon wear, especially when cutting hard rock is particularly true; sintered diamond wire cutting speed is relatively slow, but life is very high. The two types of beads, diamond randomly distributed in the carcass, dominated by mechanical means. The disadvantage is that the diamond particles are not fully exposed for effective cutting, but also because of the role it serious loss of pulling force. Further, the diamond particles are arranged at random diamond often unevenly distributed, resulting in a high concentration region of diamond, diamond can not be sufficiently many effectively utilized, wasteful, and tends to clog the chip channel; and a region of low concentration in the diamond some neighboring diamond diamond particles due to lack of reinforcement. Overload, it is easy to break. Can not be effectively cut.

 

Saw compared with electroplated diamond wire, diamond wire hot carcass performance tuning range, the carcass of the strong grip of diamond, suitable for cutting granite and concrete cutting and other hard objects, which occupy the market in wire saw 2 / 3 share.

 

Practice found that domestic R & D hot Diamond Wire Saw widespread following questions:

(1) The carcass performance and cutting objects do not match, the process of using diamond grain out serious, there are cutting efficiency and life is a big gap with the international advanced level;

(2) beaded matrix and substrate bond is not strong, the phenomenon of the carcass part off the block and the overall loss of more serious;

(3) the effect of the difference between the fixed beaded, some beaded wire around the presence of axial rotation and along the rope string action phenomena;

(4) broken rope rope frequent, short life.

 

In order to solve the problems in the course, the large number of exploratory research after that in the development of Diamond Wire Saw hot pressing process, the key technical issues that must be addressed are:

(1) beaded matrix formulation design, including how to improve the metal bond and diamond gripping force and matrix and the matrix bond strength;

(2) beaded manufacturing process, including beaded cold, hot and corresponding mold design;

(3) beaded fixing material and fixation techniques.

In these three techniques, matrix formulation design and manufacturing process is particularly important.

 

In order to solve the above problem, Taiwan and China wheel company (KINIK) has developed a type of brazing diamond wire saw beads. Such beads on the diamond by brazing into firm grip on a substrate, this method allows uniform distribution of diamond particles. Each capsule can effectively cut diamond, thereby reducing the amount of diamonds, to avoid waste, but can also make chips unimpeded. Practice shows, DicGrid brazed diamond wire cutting efficiency type is common type of diamond beads four times.

 

Brazing with electroplated diamond tool manufacturing comparison:

Conventional plating process and the brazing process is also specialized in manufacturing single diamond tools, to compare the characteristics of the two processes can be expected to prospects of their application.

 

Dimensional accuracy: Plating (outer coating) and brazing two processes are based on steel substrate as the substrate. Each in different processes on the steel substrate coated with a layer of diamond, diamond-coated precision Lin Zengdong considered both are similar, but, for a larger size tool, the plating process the brazing process more accurately than a little. The reason is subjected to a brazing process inevitably heated to high temperatures (e.g. 800-1000 ℃), so that the steel substrate deformation occurs in the thermal expansion and contraction of the micro-process, and is sufficient to affect the dimensional accuracy of the tool.

 

Grinding efficiency: brazed diamond tools diamond protrusion height can be 2/3, so high grinding efficiency, and is conducive to scour debris, easy abrasive surface grinding capacity lost due to blockage.

 

Diamond particles arrangement: single diamond plating method to bury the sand sand, diamond showed a dense and chaotic state arrangement. Brazing method can be ordered diamond particles, gold cut stone can be diluted to close. Saving Diamond, and it helps to adapt to different grinding or other requirements.

 

Diamond tool life: brazed diamond particles and brazing alloy metallurgical combine, he incurs firmly welded, electroplated diamond tools and diamond particles are merely plated metal deposition mosaic, no metallurgical bond between the two, when the diamond wear exceeds the maximum section, must fall off, so brazed diamond tool life is higher.

 

Effect of diamond properties: brazed diamond tools diamond must withstand high temperatures, although the time is very short. But close enough to make a full diamond azelaic strength decreases, so you must use a good thermal stability of diamond, and the reaction is not intense brazing alloy and diamond surfaces. If the heat for a long time, or the improper selection, will cause damage to the surface of the diamond, and some may even undermine cohesion between the two.

 

Production cycle: As plating layer deposition, thick, generally 5-1-um / h speed, which determines the electroplated diamond tool production cycle is very long; brazed diamond tool manufacturing is highly efficient, depending on the speed heating method, the right way, about ten minutes to complete, and is independent of the choice of the thickness of the diamond particles.

 

Manufacturing cost of brazing diamond concentration can be controlled. Can be dense sparse can save diamond brazing alloy dosage can also be controlled.

 

Electroplated diamond beads carcass type convex shape; sintered diamond beads gently shaped carcass shape; and brazed type diamond beaded diamond brazing due to wetting. Its carcass is concave shape. Due to the different shapes of the carcass, ordinary type beaded diamond protrusion height restrictions in highly abrasive 1/3: The brazing type beaded edge of a height of up to 2/3. Common type made of gold diamond beaded generally only contain O.5 carat diamond; and DiaGrid brazed type diamond carat diamond beaded Ol-only, though a small diamond content, but each piece of diamond can work effectively, not only reduce costs, but cutting performance improvement, when sawing granite and marble, its life similar general type. In the production of diamond wire soldering type, it is important to use high-strength, quality and stability of the diamond, such as DeBeers company SDAl00 + (particle size 40/50). DiaGrid brazed diamond wire through extensive testing in the United States, Germany, Italy and Taiwan, to obtain satisfactory cutting performance.

 

The minimum diameter of the beads is about ordinary 8mm, while the smallest diameter DiaGrid brazing type beads is 6mm, this beaded currently widely used in the world machining complex shapes stone products [1].

 

As the carrier beaded rope, wire saw for cutting a significant impact. If the rope life is short, frequently broken rope, beaded cutting performance can not be reflected. The study found that to improve the life of wire rope, wire rope should improve fatigue strength, in all of the mechanical properties of the wire rope, wire rope is the most critical indicators of fatigue strength. 8.5mm diameter wire saw, for example, saw the rope length 14.8m, cutting line speed of 30m / s, rope saw each turn, by bending straight, straight to bend by alternating cycles twice. Use a wire saw for about 500-1000h (due to different cutting object width varies), at least 3.8 million times the cycle, curved straight loop 700 million times. Not to mention also because the machine does not operate very smoothly and with high frequency vibration using wire saws. Therefore, the rope must have a high resistance to fatigue in order to meet the requirements of wire saw use.

 

Beaded fixation techniques, with a spring fixed, fixed plastic or rubber, plastic or rubber composite spring + fixation methods commonly beaded fixation. And a spring fixing method compared to plastic or rubber is fixed to the following two advantages:

(1) plastic or rubber wrapped up the rope, carrying the rock powder to prevent cooling water corrosion and wear rope;

(2) fixed on the rope beaded reliably prevent rotation and beaded string action, make beaded matrix hole can not wear a wire.

Therefore, strong abrasive cutting material such as granite and concrete etc. to use a method of fixing a plastic or rubber. Spring + plastic or rubber compound can be more reliable method of fixing the beads fixed on the rope, but the high cost of manufacture.

 

Diamond wire saw can cut thicker plates, circular saw blades than the much thicker cut, cutting speed faster than the gang saw. Different from ordinary tool is that it can be directly sawing at the scene, while the ordinary tools was sawing at the factory. Practice shows that the multi-wire saw cutting granite group, saw its high efficiency than row, both straight cuts, but also cut the curve, you can put the stone cut into more complex shapes.

 

Because wire saws have these characteristics. Therefore, the application in the field of wood processing right on the rise. Present in all of the world's diamond cutting products, diamond wire saw, accounting for almost 10% of the market share is expected to grow rapidly in the future.

 

In recent years, diamond wire saw and band saw diamond mining joint exploitation of the marble to be fully applied, as people mention marble cutting mining technology provider, Diamond Wire Saw for further understanding, there is reason to believe that in the near future diamond wire Saw will be widely used in the mining of marble, so that our mining technology has reached the world advanced level.

 

In order to improve production efficiency and quality of diamond wire saw process, reduce costs, use reasonable parameters is essential. To this end, 刘宝昌 et al [2], on the basis of theoretical analysis and experiments, on the track and sawing diamond wire saw cutting mechanism were studied the following conclusions:

(1) diamond wire saw for cutting curves approximate a circle involute, saw unit length of rope tension and pressure on the stone saws 绳施加 determines the shape of the involute;

(2) diamond wire saw cutting line, high-speed, single-particle diamond sawing process facilities applied pressure on the stone is small enough to produce the stone crushing volume, the main way is crushed rock crushing Hertz (HertzianFracture), mainly in the the way to achieve high-speed grinding cutting, so the chip size small;

(3) According to the mechanism of crushed rock diamond wire saws, cutting saws hove force should be properly controlled to ensure that saw some rope line speed, use good wear resistance of diamond and the carcass, to ensure good cooling. To improve the cutting speed and extend the life of the saw rope.

 

Diamond wire saw cutting fight floods wreck. December 14, 2002, Tricolor cargo from Zeebrugge (ZeebrUgge) bound for Port 南普敦 Port (South- ampton) on the way, due to the thick fog, with the German container ship bound for Kariba (Kariba) in Hong Kong cargo ship collided with a variety of cars equipped with 3000 (Audi, BMW, Volvo and Saab) on Tricolor cargo ships, cranes, bulldozers, sank half an hour after the collision. After the accident. The relevant authorities to fight floods Tricolor wreck decision immediately. Captain Tricolor No. 190m, width 32m, 13-ton cargo holds 27,000. The company commissioned by the Netherlands SMITSALVAGEB.V floods hit, because the company beat the Russian Kursk waterlogged (Kursk) Tyrants boats have had a brilliant time score. In order to fight floods cargo ship, the multinational group to conduct a careful investigation, decided to use a diamond wire saw technology to its shipwreck sawn 3000 tons heavy pieces, and then transported to a one Zeebrugge processing, obviously this is the use of diamond wire Saw fight floods wreck technically a big step forward. [3]

 

Diamond Wire Saw is compared to the use of flexible tools were stone mining and stone processing equipment, especially in the granite mining, with traditional flame cutting, blasting and other methods, the recovery of the stone blocks regular shape, neat, eliminating the subsequent block squaring process greatly improves the yield catch, and in the production process, low energy consumption, low vibration, low noise, no dust, environmental friendly and good, very obvious superiority.

 

Due to the high hardness of granite, in the recovery process on beaded loss is still large, in order to solve the above problems, Zhang Jinsheng, etc., for Diamond Wire Saw for Isle of red granite mining beaded rope wear performance and cutting speed relationship wire Saw preload and other process parameters were studied, said:

(1) Diamond Wire Saw granite mining and processing mechanism is grinding and swipe, Diamond Wire Saw line speed is high, single-edged diamond cutting suffered little pressure, the wear patterns of the diamond particles are mainly abrasive wear , partial broken under certain processing conditions, there is an optimum cutting speed, so that the minimum beaded rope wear, cutting the highest rate. For Isle of red granite ore in preload is about 1800N, the best recovery rate in the 2lm / s-23m / s range;

(2) within a certain range of operating speeds, preload the larger diamond wire sawing beaded rope greater the force, the higher the efficiency, the lower the wear resistance of beaded rope. Integrated Diamond Wire Saw Wire Saw mining efficiency and wear resistance, Isle of red granite mining preload reasonable ranges 1600N-1800N;

(3) Diamond Wire Saw for granite mining, job security, low noise, cutting stone structured, kerf is small, environmentally friendly and good. General economic and social benefits significantly, broad application prospects.

 

Research wire saw in China started late, but the pace of development is very fast in recent years. Because of its excellent performance in the structure of hardness and softness. Processing methods with energy saving, environmental protection advantages, will become increasingly expanding its scope of application. Rarely seen reports on domestic and international wire saw production, according to the literature [7] estimated that the world's annual consumption of about 1.5 million meters, valued at $ 50 million. Value of domestic wire saw annual consumption has exceeded 20 million yuan; and still rapid development among the various positive factors determine our wire saw has a bright future. These factors include macro factors, the economy, such as the rapid development of the country, the importance of environmental protection; also includes factors aspects of the industry, through the joint efforts of the whole industry, China's is the world's first synthetic diamond producing countries, diamond single crystals production and some of the traditional tools such as blades, wheel production, profits have been very modest, one must look for high value-added products. Development wire saw technology because of its high degree of difficulty and development is lagging behind in recent years, due to the small domestic manufacturers to maintain better benefits, and have good prospects for development, the transfer of industry will greatly promote the development of wire saw.

 

More rope rope saw the emergence of more than 60 for the development of rope saw the opportunity to bring to an alternative to traditional sand Sawing big board for possible; the rapid development of digital control technology, people increase of shaped stone, development of wire saws are a good opportunity to bring the current foreign beaded rope achieve minimum 3mm. Allegedly, Guilin Research Institute of Geology in 2000 completed the diameter lOmm sintering injection-type wire saws development, its performance up to 80% -90% of foreign advanced level, and has a price advantage; in recent years on the diameter of 8mm success. The gap between the two millimeters spent three full years. These technological breakthroughs, will bring rope saw accelerated development [8].

 

China's current rapid development of the construction industry, particularly in urban demolition, renovation of enormous quantities, wire sawing applications market in this area is very broad. Rope saw the construction sector, foreign general use brazing injection type, in many cases the use of dry cutting machining, its huge market potential worth Insiders worked for.

 

Currently sawing granite and other hard stone slabs are made of sand saws, heavy pollution and low efficiency, and produce large amounts of waste sawing; multi-wire saw the emergence of rope to make beaded wire saw process in this - in the field of competitiveness greatly improved, and has high efficiency, small footprint, low power consumption, less waste and so on. While processing costs higher than the sand saw about 20%, due to the continuous development of wire saw cutting technology, the cost has been declining, with energy saving, environmental protection, etc., I believe that in the near future will replace sand saws, occupy hard stone large board processing this huge market.

 

Wire Saw is currently mining in Western countries are indispensable tools. In our country, for the majority of the owners in the mining blocks for medium and small enterprises, rough mining methods, it is impossible for an expensive rope saw mining equipment, resulting in a large number of stone resources consumed, with the national resources and environment attention: With the accumulated technology related businesses, funds: wire Saw this advanced tool for mining companies will eventually be accepted and greatly enhance the level of domestic technology in this field.

 

Rope saw a very wide range of applications, the work environment vary widely, require the production of wire saws must be highly targeted to produce wire saws with different properties to meet different requirements.

 

High levels of foreign wire saw from its technological leadership in all aspects. High quality, special alloy powder, granulation technique and advanced diamond plating technology, sophisticated high temperature brazing techniques, etc., are important conditions for technical success. In China, most of these technologies is still in the research stage. A successful product, the need to support many successful technologies and products; on the contrary, a good product but also give many related products and technologies has brought tremendous opportunities. China's wire saw manufacturers should collaborate with related industries and common development; similarly, the relevant industry insight rope saw this development should seize the opportunity to improve the technical level, to achieve an alternative foreign technology and products.

 

Currently, the domestic diamond wire saw is basically limited to the use of special processing of stone and other more areas rarely involved. From our point of view of the environment, the economy over the years has been the rapid development of the urban landscape changes rapidly, these decisions in the construction, demolition, and many other aspects of diamond wire saw promising. Industry insight should accelerate brazed wire saw development or design a beaded rope such requests quickly capture this huge market.

 

In other countries, more than 60 multi-wire saw the emergence of rope, wire sawing trend instead of sand granite slab sawing increasingly evident; With this breakthrough wire saw equipment, will bring huge market; the current production certain types of beaded rope is almost the same in terms of quality compared with similar foreign products, and has certain advantages in terms of price, can enter into foreign markets.

 

                                                                       - Excerpt from "Baidu Library"