Effects of Controllable and Uncontrollable Parameters on Diamond Wire Cutting Performance Using Statistical Analysis: A Case Study

Abstract

Nowadays, most mining and quarrying industries utilize a diamond wire saw machine for bench cutting operations. This method uses a metal wire or cable assembled by diamond beads to cut the hard stone into large blocks. Many parameters classified into controllable and uncontrollable parameters affect the performance of the diamond wire saw cutting method. The uncontrollable parameters are related to rock engineering properties, and controllable parameters are related to operational aspects and machine performance. The diamond wire sawing process’s production rate is one of the most critical parameters influencing the design optimization and quarrying cost estimation. The cutting rate and wear rate of diamond beads are the most important factors to evaluate quarries’ production performance. This study aims to determine the effects of different controllable and uncontrollable parameters on different quarries’ production rates. Rock engineering properties like strength, hardness, and abrasivity, and operational aspects, such as cutting angle and drive wheel diameters, are considered as the main factors affecting the production performance of the diamond wire saw method. To discover the influence of these parameters, a detailed investigation in ten quarry operations was carried out. The relation between cutting rate and diamond bead wear with different parameters is estimated. It was observed that different controllable and uncontrollable parameters could increase or decrease the cutting rate and diamond bead wearing. Furthermore, using simple and multiple regression analysis, performance prediction of the cutting rate and wearing of diamond beads was developed, and the best equations were proposed.

Energy consumption and wear rate of diamond beads during operation of a diamond wire saw

“…In most mining machines, regardless of the rock mass excavation mechanism, uniaxial compressive strength has a decisive influence on their efficiency and is an important factor in many rock mass classifications. In this regard, diamond wire saws are not an exception, which is corroborated by previous studies, [6], [7], [8]. The results of the said studies show that the cutting speed and sawing efficiency decrease with increasing strength of the rock being sawn.…”

“…Yilmazkaya and Özcelik 2016 established a significant dependence of the degree of wear of diamond beads and uniaxial compressive strength and a slightly smaller dependence with tensile and impact strength, [21]. They also found that by increasing the abrasiveness value determined according to Böhme, the wear of the beads [6] found that when cutting marble, the wear rate of beads increases with increasing uniaxial compressive strength and hardness determined by the Schmidt hammer, and decreases with increasing abrasion. In addition, they found that an increase in the cutting angle increases the wear of diamond wire, that is, the wear of beads is higher when sawing a horizontal cut than with a vertical cut.…”

“…The results of the said studies show that the cutting speed and sawing efficiency decrease with increasing strength of the rock being sawn. Although to a lesser extent, hardness, abrasiveness, brittleness also has a significant influence on sawing efficiency, [6], [9], [10].…”

“…Rasti et al 2021 measured the performance and wear rate of diamond wire in limestone, travertine and marble quarries, [6]. Analyzing the measured data, the authors found that by increasing the cutting angle in relation to the bench face, the efficiency decreases while the wear rate of diamond beads increases (Figure 7.a).…”

“…Figure 7 a) Influence of cutting angle on sawing efficiency b) Influence of drive wheeldiameter on sawing efficiency,[6] …”