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The development of diamond wire saw
Publish Date:2020-10-16
Since the advent of diamond wire saws, it has been a process of continuous innovation in the manufacturing process of wire saws, as well as a process of continuous development and expansion. At present, there are more than 8,000 wire saw machines for mining marble in the world, and more than 17,000 wire saw machines for mining granite. The number of wire saws machines for block shaping and cutting is increasing. and there are also increasing cases of using wire saws in large-scale engineering reconstruction such as for building demolition and maintenance. Studies have shown that diamond beads are still the main factor in the cost and benefit of diamond wire saw cutting. Therefore, a series of innovations have been made at home and abroad around the manufacturing process of beads.
(1). The types of beads have formed the first generation electroplating type, the second generation sintering type and the third generation high temperature brazing type;
(2). The third-generation high-temperature brazing type is widely used because of its high cutting efficiency and long life;
(3). Diamond wire saw is developing towards small diameter;
The important finding from the experiment is that the use of a smaller diameter wire saw will significantly reduce the feed pressure. A wire saw with a diameter reduction of 25% will reduce the feed pressure by more than 25%. Compared with the operation of ordinary wire saws in the sawing process, the wear and deflection of small diameter wire saws are reduced to a very low level.
In short, the current wire saw machine used in construction sites are too large in structure and do not meet the ergonomics requirements from the perspective of ease of operation and movement. To this end, a small and light wire saw machine with multiple functions is needed. The newly developed wire saw machine can be installed and operated by a single person. The various parts of the machine are easy to install and disassemble, and each part weighs no more than 25Kg. Due to the use of newly developed wire saw tools, this machine will produce less waste, lower noise and less pollution, which makes the superior performance of the wire saw more prominent.
At first, diamond wire saws were only used for mining natural stone. The first generation of diamond wire saw beads were electroplated, and later a sintered type was developed. The diamond on the electroplated bead is held by a nickel binder; the diamond on the sintered bead is held by a metal binder (such as cobalt). The former contains a single layer of diamond, while the latter is a multilayer diamond. The cutting speed of electroplated diamond beads is relatively fast in the initial cutting stage, but they will wear out very quickly, especially when cutting hard rock; the cutting speed of sintered diamond beads is relatively slow, but the service life is longer. On these two types of beads, diamonds are randomly distributed in the matrix and controlled by mechanical means. The disadvantage is that the diamond particles cannot be completely exposed for effective cutting, and they will be seriously worn out due to the pulling force. In addition, the random arrangement of diamond particles often results in uneven distribution of diamonds. As a result, many diamonds cannot be fully and effectively used in areas with high diamond concentration, resulting in waste and tending to block the chip evacuation channel; and in areas with low diamond concentration, some diamond particles cannot be reinforced by neighboring diamonds. The load is too heavy, so it is easy to break. Effective cutting cannot be performed.
Compared with the electroplated diamond bead wire saw, the hot-pressed diamond bead matrix has a large performance adjustment range, and the matrix has a strong holding power on diamonds. It is suitable for cutting hard cutting objects such as granite and reinforced concrete. Therefore, it has 2/3 wire saw market share.
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