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Abstract: This paper introduces the composition and manufacturing method of diamond bead rope, and studies the mechanism and process of diamond bead wire saw processing stone and its application in stone block mining.
Key words: diamond rope according to stone application
1 Introduction
In recent years, diamond bead wire saws have been widely used in the stone industry due to their short preparation time, flexible cutting, low noise, low dust, low pollution and energy saving. The beaded rope itself combines the rigidity of the diamond with the flexibility of the rope, making it adaptable to such things as block mining. This unique sawing mode is not possible with other diamond tools; in addition, the beaded rope is almost not in length. Restricted, its applicability is strengthened, and it will play a unique role in some special occasions such as underwater processing and building demolition. In order to promote the development of China's stone industry, the author discusses the application of diamond bead rope and some experience, for the stone processing enterprises to learn from and reference.
2The composition and manufacture of diamond bead wire saw
2.1 The composition of the diamond bead wire saw
The structure of the beaded rope is shown in Figure 1. A number of diamond bead particles are sleeved on a multi-strand wire rope, and the adjacent beads are separated by a spacer sleeve that supports the fixing (similar to a necklace). The diamond bead wire sawing process is completed by the diamond bead rope directly involved in the cutting and the corresponding mechanical equipment (ie, the wire sawing machine) for driving the beaded rope movement. Before the processing, the beading rope of a certain length is docked end by end with a butt sleeve such as a copper sleeve. Form a closed loop. During processing, the closed-loop bead rope tensioned on the wire guide set of the wire saw machine is driven by the driving force to perform high-speed movement of the bead rope, and the cutting is realized by the grinding motion of the bead. .jpg)
2.2 Diamond bead rope manufacturing process
(1) Diamond beading
From the invention of the diamond bead rope to the present, the improvement of the beading process has never stopped. At present, the diamond bead manufacturing process is mainly based on electroplating and hot press sintering, and the latter dominates. Although some scholars in Taiwan have successfully fabricated brazed diamond beads using brazing methods, large-scale engineering applications have not yet been realized. The figure shows diamond bead samples prepared by these three processes, respectively. Sintered bead has high wear resistance. By adjusting the ratio of each metal component in the carcass or selecting diamond abrasives of different grades, particle sizes and concentrations, the carcass wear rate and the diamond abrasive wear rate can be adjusted to produce beading with different edge height and space to adapt to different Cutting of the material. Compared with hot-pressed sintered beads, the electroplated diamond bead fabrication process is relatively simple, and is more conducive to bead diameter reduction. Because the diamond coating is thin, the carcass wear resistance is poor, the plating metal has limited holding force on the diamond abrasive grains, and the diamond abrasive grains are easy to fall off in advance, so the overall performance is not as good as the sintered bead, which is not suitable for cutting granite. Mainly used for the cutting of soft materials such as marble.
(2) Isolation sleeve
Isolation sleeves are used to isolate and fix adjacent beads. There are three types of isolation sleeves commonly used in engineering. The spring washer type is the earliest form of isolation sleeve. Because the spring washer type isolation sleeve is easy to enter from the gap between the beads, the spring and the gasket during the processing, the wire rope is abraded under the bending motion of the wire saw, thereby causing the bead rope to break. Especially when processing granite with high quartz content, the corrosion resistance of the steel wire rope is quite serious due to the high hardness of the quartz, so the isolation sleeve is suitable for the cutting of soft materials. It has been used less frequently. In order to meet the needs of high hardness material cutting, injection molded and glued isolation sleeves have been developed. The injection molding and injection molding type isolation sleeve is made of wear-resistant plastic and rubber as a spacer between the beads. The beading and the wire rope are completely filled with plastic and rubber, thereby preventing the grinding debris from entering between the bead and the wire rope and abrading the wire rope. It is the emergence of the bead wire saw to expand the processing of granite high hardness materials. Among them, the injection molding type is the most widely used, and the bead wire saw with the injection rubber as the isolation sleeve is mainly used in the stone mining area below freezing degrees in the colder regions. This is because the low temperature performance of rubber is better than plastic, and it is still at low temperature. Can maintain good flexibility and strength without brittle fracture.
(3) Wire rope
Since the bead is fixed on the wire rope and cut downwards, the wire rope can be regarded as the "ridge" of the beaded rope. During the use of the bead wire saw, the wire rope often breaks the rope due to fatigue wear, abrasion, chemical corrosion, etc., especially when the processing area reaches a certain amount, the rope breaking phenomenon is more frequent. Broken rope not only affects production, but also brings unsafe hidden dangers such as smashing beads, so the performance of the rope is crucial for the use of beaded rope. In addition to the performance of the steel wire itself, the life of the wire rope is also related to the pre-tensioning tension during processing, the minimum curvature of each guide wheel, the axial load of the bead during processing, and the impact load. Therefore, the product of the professional wire rope manufacturer should be selected. Refer to the relevant instructions for the wire rope when using it.
3 wire saw processing stone general process
In actual work, there are many kinds of stone sawed by beaded ropes. The conditions of sawing are very different. In the mining, special-shaped stone processing and building demolition, the sawing process is difficult to compare. In this paper, only the typical processing of beaded wire sawing and cutting materials is used to analyze the change of sawing curve and related laws when beading wire sawing stone.
3.1 flattened by the tip
The beading rope cutting mechanism and process are very complicated. For the convenience of description, the beaded rope is assumed as follows: it is completely soft in its radial direction, that is, it does not bear any bending stress; it is completely rigid in the axial direction, and cannot have Any tensile deformation. Under this condition, the initial sawing curve of the beaded rope completely coincides with the surface of the sawed stone material, as shown in the first curve in Fig. 2, including the AB, BC, and CD sections. At this time, the inside of AB, BC, and CD tends to infinity due to the radius R, and the sawing force is zero, and the wear rate is zero. Sawing is actually carried out only at four points A, B, C, D, so that the sharp edges on the four corners are quickly smoothed and extended to the adjacent parts. Finally, the arcs AB, BC, CD become a piece. A smooth curve, as shown by curve 2 in Figure 2. This process can be referred to as "flattening from the tip."
3.2 by the flat circle
Beaded rope processing stone, the change of the sawing curve is basically a process of rounding from the square. In curve 2, although the sharp corners are flattened, the radius of curvature of the entire sawing curve is still very different. The position of the original four corners and the vicinity, the R value is much smaller than other places, and the sawing speed will be far. Far faster than other parts, so the radius of curvature of these parts is gradually increased, and the R value away from these parts is correspondingly smaller, and the radius of curvature and wear speed of each part of the whole wear curve reach a certain balance, as shown in Fig. 2 Curve 3 in. At this time, the top end of the wear curve is approximately arc-shaped, so the process is called "flattened from flat". This process may take a long time in the sawing of the stone material, and the steady state of the curve 3 may not be formed due to the different initial conditions of the sawing. During this sawing process, the curvature of the two points A and B is continuously reduced, and finally the curvature is reduced to zero and the sawing is stopped. At this time, the arc AB, the arc DC and the loose edge and the tight edge which do not participate in the sawing form two straight lines. At B and C, the larger sawing speed increases the radius of curvature, the arc BC sawing speed is gradually balanced, and finally close to the semicircle, while the line AB, DC becomes the tangent of the arc BC, the tangent point They are B and C respectively. In the process of sawing curve from flat to round, the corresponding central angle is getting smaller and smaller, gradually decreasing from the initial greater than 1800. When the side of the sawing curve AB, the sawing speed of the DC section gradually becomes slower and finally becomes The line is stopped and the sawing is stopped, and the corresponding central angle is 180 °C. At this time, the actual sawing curve of the beaded rope is limited to the arc portion BC on the tangent point, and the actual length of the sawing curve is significantly shortened.
3.3 stable sawing
Curve 3 is a very interesting stable sawing state, the top of which is close to the semi-circular arc, and the tangent of the two points B and C is recombined with the loose side and the tight side. The distance between the two straight lines and the driving wheel When the diameter d is uniform, the entire system stops sawing in the longitudinal direction (i.e., the AD direction), and in the lateral direction, the sawing speeds of the points are equal, thereby maintaining the stability of the shape of the sawing curve. In the whole process of bead wire sawing stone, the shape of the sawing curve is in the adjustment and change in most stages. The inside of the sawing curve constantly adjusts its curvature due to the different cutting speed, and the boundary condition changes again. The sawing curve is affected, and only in the case of curve 3, various factors are balanced to maintain the shape stability.
The shape of the top end of the beaded wire sawing curve is close to a circular shape. The tension of the beaded rope caused by the sawing force is small at the loose side and large at the tight side. The tension is different, which will inevitably lead to different pressure of the beaded rope against the stone, and the pressure is large. The tight edge sawing speed is faster than the loose edge, so that its curvature is further reduced and slightly smaller than the arc; in contrast, the curvature of the loose edge will be slightly larger than the arc. This maintains the balance of the entire sawing curve. At the same time, due to the increase of the tension, the arc advances, making the point C closer to the point D, and the opposite of the point B, so that the length of the AB line is greater than the actual sawing curve of the sawing curve of the DC0 stable sawing stage. The length and shape of the curve remain unchanged, so the curve is stable under stress, and it is an ideal sawing state without adjusting the initial tension of the system.
3.4 Residual sawing
After the stable sawing, the cutting point B, C gradually approaches the edge A, D. When the C point on the tight side first coincides with the D point, the edge condition of the curve will change, the balance of the curve 3 is broken, sawing Enter the residual sawing stage. At this stage, the center angle corresponding to the sawing curve continues to decrease from the original 1800, the length of the sawing curve is rapidly shortened, and the pressure of the bead string increases per unit length, and the initial tension of the system must be adjusted in time to avoid beading or Diamond is destroyed by excessive pressure.
4 wire saw cutting for stone block mining
4.1 Preparation of stone blocks before mining
The use of diamond beaded ropes requires certain conditions. Generally, in open pit mining, there must be power, water and highways. At the same time, it has lifting equipment, transportation tools, large sites, and the thickness of the ore layer is at least 500mm and a relatively complete shape. . The use of diamond beaded rope to mine stone requires a series of preparatory work.
(1) Punch
Punching is a key preparatory work. If the hole is not well-fed, it directly affects the piercing of the beaded rope, affecting the service life of the rope and the cutting efficiency. Therefore, the punching process is particularly important.
To cut a large piece of material, you must make three holes, one vertical hole and two horizontal holes. The three holes intersect at one point (as shown in Figure 3). This is the most ideal way to play. If the three holes do not intersect at one point, then the following will occur: a. The perforation of the diamond bead rope is troublesome, even impossible to wear, then Re-punching, which reduces production efficiency. b. Even if it is punched through, the cutting will have an effect on the life of the beaded rope. Because the rope is bent and folded in multiple times in the hole, the wear of the rope is more harmful, thus reducing the service life of the beaded rope. The hole must be carried out according to the actual conditions and according to the operating procedures. .jpg)
(2) stringing through hole
At present, when the domestic stone industry uses beaded ropes, most of them use the artificial stringing method, that is, the one end of the rope is fixed with a plurality of loops of soft loops, which are threaded from one hole and pulled out from the other hole by wire, so that the Shenzhu rope is passed through. .
(3) Installation equipment
After the beaded rope is punched through, the equipment is installed. Due to the heavy equipment and the need to re-adjust the equipment after cutting a plane, a lifting device must be equipped around it to be installed at any time.
(4) Water supply
When cutting stone, because the wire speed of the rope is large, the friction between the stone and the stone is large. If there is not enough water or water, the heat between the rope and the stone will generate a lot of heat, which will not only deform the spring and the wire rope, but may even melt and stick the spring. Together, losing flexibility, this will reduce the life of the beaded rope. In order to ensure the quality and longevity of the rope, water must be supplied and the water supply must be added along the direction of the rope.
4.2 Cutting of stone blocks
When cutting marble blocks with beaded ropes, you must first cut the horizontal plane and then cut the vertical surface to ensure the smooth cutting. The cutting method generally involves cutting the horizontal plane first and then cutting the vertical surface. If the vertical surface is cut first, and then the horizontal plane is cut, when the horizontal plane is to be cut, the stone that is suddenly cut is cracked, the bead rope is pressed, the cutting cannot be performed, the motor is idling, and the bead rope is deformed.
The beaded rope is not only used for mining blocks, but also can process all kinds of stone arcs, special shapes, foundation stones, etc. The wire sawing machine has high line speed, high efficiency, high precision, curved type, arc form and linear type. It is equipped with two types of computer control and profiling.
5 Conclusion
At present, diamond bead rope has been widely used in China's stone industry. Many domestic stone materials have introduced advanced technology and equipment, using diamond bead rope to mine stone and processing various shapes of plates (mainly shaped plates), which has production efficiency. High, good product quality and low cost embodies the new development of modern industrial production technology. It is of great significance to obtain high quality blocks and various shapes of plates, improve the processing quality, production efficiency and economic benefits of stone. With the successful application of multi-rope side-by-side cutting technology, it directly challenges traditional frame saw sheet cutting methods, making efficient and low-cost cutting of large or very large sheets a reality. People are increasingly aware of the superiority of beaded ropes in stone processing.
Application of diamond bead wire saw in stone processing
Yang Zhihong Wuhan University of Technology