Current situation and problems of diamond beaded saw in Chinese stone industry

With the continuous deepening of the strategy of resource conservation, sustainable development and circular economy implemented by the central government, it has become an urgent problem to be solved in the stone industry in recent years to eliminate waste, improve material yield and popularize advanced mining methods and equipment. At present, the most popular is to popularize and apply the diamond rope saw mining in China. Since 2005, the Chinese stone mining machinery industry, which has been silent for many years, has made great breakthroughs, and the most prominent manifestation is the localization of Diamond rope saw. Almost at the same time, several enterprises, such as Shanghai Morgan, gaoshi stone mining machinery, henan united cyclones, quanzhou edge tools, fuzhou tianshiyuan, launched their own diamond rope saws, together with the original research and development of the guangdong bureau of geology and mineral exploration machinery factory and other enterprises, which made the market competition of diamond wire saw suddenly become fierce. The appearance of this phenomenon indicates that the era of the popularization of diamond rope saws in Chinese stone mines has come, which will bring revolutionary progress to the improvement of Chinese stone mining level.

The application of diamond rope saw to mining stone has a history of more than 30 years in foreign countries. In the early period, the rope saw was only used to cut soft stone, and the technology of the rope saw to mining marble mine in the world has been very mature. For granite and other hard stone, after the rope saw, beaded wire manufacturers and mining enterprises long-term unremitting efforts, with a rope sawing of granite mining technology is more and more mature, the wire saw can be widely used in granite, sandstone, etc on the hardness of stone mining, product quality is higher and higher, more and more low cost, has become a worldwide trend.

Compared with the traditional mining method of "blasting + flame cutting", the advantages of using the rope saw in stone mining are as follows:

1. Wide adaptability, rope saws are applicable to all types of mines, while flame cutting is only applicable to granite mines with high quartz content and less cracks.

2. Powerful functions and high efficiency. First, the mining depth is deep and can reach l0 ~ 20m or even deeper. Secondly, the cutting speed is fast, generally reaching 3 ~ 4m2 / h, which is 2 ~ 3 times of flame cutting.

3. The rope saw can cut in all directions, such as vertical, horizontal, and inclined plane, and can also be cut blind, while the flame cutting can only be cut in vertical plane.

4. High completion rate and low overall cost. Firstly, the cutting surface of the rope saw is very smooth and will not cause any internal injury to the waste materials. However, the cutting surface of flame cutting is rough and rough, and causes certain internal injury to the waste material. Besides, the large saws, usually ranging from 100 to 300mm, cause great waste of resources and high mining cost.

5. Safe and environmental protection: rope saw mining is noiseless and dust-free, and it does not affect nearby residents and other operating surfaces. Besides, it is highly automatic with separate control and low labor intensity and high safety. However, the noise and dust of flame cutting are very large, which seriously affects the work of nearby residents and other workers. Besides, the labor intensity of workers is high and the safety is relatively low. To sum up, in today's increasingly scarce resources and soaring oil prices, mining granite with rope saws has remarkable economic and social benefits.

The factors that restrict the production and application of diamond rope saw although the mining of diamond rope saw has advantages that traditional mining methods cannot compare with, there are also a series of technical difficulties in the application of new diamond rope saw in actual production, including high cutting efficiency, long life, low price and high reliability. As a annular chain, diamond saw has to be strengthened as much as possible. The reliability of diamond saw is a great problem. The damage of the saw will result in the failure of the whole tool or greatly reduce its life, which has a great impact on the design of tool and the production of diamond saw.

Nowadays, the production of diamond saw has not been mastered by many diamond tool manufacturers. On the one hand, it is because the production of diamond saw is more complicated than that of circular saw. On the other hand, the production of natural stone sawing saw requires the close cooperation and cooperation of diamond saw manufacturers and end users. A variety of factors related to diamond saw include: the sawing life of beads, the cutting speed of beads, the spacing between beads on the saw, the die design, and the life of steel rope under normal working conditions.

1. the most common problems

1.1 The most common problem that the rope saw cannot cut and use is improper selection of diamond (usually too good diamond), matrix, bead spacing, mold design or wrong application parameters. For example, if we choose too high diamond density or too good diamond, its sawing performance is not very good. The diamond will not shatter, making it difficult to produce new sharp edges.

1.2 Saw fracture saw wire rope fracture, usually is to use the wrong application parameters or rope saw the poor quality, which means that the plastic/rubber and combination between diamond beads not firm, lead to debris into diamond saw rope, quickly magma or cuttings in beaded steel body with steel rope part contact and friction between steel rope, steel rope connection thread begin to fracture, which may be due to errors using settlement agent. It may also be due to improper selection of wire rope, beaded steel body and poor heat treatment after injection molding.

1.3 Peeling off. If the cutting layer of the bead falls off from the steel body, the improper selection of the tire body or the wrong sintering parameters are usually used. Improper cold pressing is often used as a cause of spalling. Paraffin may also be infiltrated between the metal matrix and the beaded steel due to improper dewaxing. Sometimes the problem is also related to improper cleaning of beads.

Loose beads and loose beads are usually a sign of trouble during injection molding. It may be due to improper use of steel wire ropes, or due to internal contamination of diamond beads or improper cleaning, which may lead to poor bonding between beads and injection/rubber.

Generally speaking, the production of diamond saw is skilled, which requires more than diamond saw blade. Like a ring chain, the production of diamond saw is composed of many different production processes. If problems occur in a production process, the whole value of diamond saw will be endangered. Many companies have no experience in this area, so it will be some time before you have a strong base of a diamond saw with good sawing capability.

In recent years, the quality and technology of diamond string beads produced by domestic manufacturers have been steadily improving, and they have reached or are close to the advanced level of imported similar products. It is mainly manifested in the following aspects:

First, the quality of steel wire rope is improved. Because imported high quality steel wire rope is widely used, the problem of easy breaking of steel wire rope is solved, and the durability of the string of beads is directly improved.

Second, the distance between beads maintains the improvement of material quality. Now high-strength plastics and rubber are widely used, which makes the combination of beads and wire rope more solid, solves the problems of loose beads and channeling beads, and greatly improves the quality of string.

Thirdly, the quality of diamond beads has been improved. Whether the beads are electroplated or sintered, whether they are cutting marble or granite, their stability and wear resistance have been greatly improved, which greatly improves the life of the string. Such as fuzhou days Shi Yuan superhard tools co., LTD and fujian several mining processing enterprises establish product test base, respectively developed marble mine rope fixed (spring), granite mining rope rope (fixed) rubber, combination wire saw (fixed injection mode, used in granite plate cutting) and other products, and can according to the special needs of customers make different cutting plan.

As an important member in the field of diamond beaded saw, we hope that the manufacturer will constantly improve the technology of diamond beaded saw, overcome the difficulties and strengthen the promotion and application in China's stone mining industry under the impetus of social forces from all walks of life, so as to improve the level and quality of domestic stone mining.