How to improve the cutting efficiency and cutting life of diamond wire saw

When people buy this kind of product, they often need to provide two parameters: the first is cutting efficiency, and the second is cutting life. The former determines how fast the wire saw cuts the stone, and the purpose is to save time costs and some other costs. The second point is how long is the cutting life under the condition of ensuring efficiency? In fact, the purpose is to increase the utilization rate of the wire saw to reduce the cost. So for wire saw products, efficiency is the core. There is no point in simply increasing the life of an inefficient wire saw. Thus, all wire saw products contain a large amount of other metal powder or alloy powder formulations, whose purpose is to increase the holding force of the matrix in order to improve the utilization rate of diamond.



To improve the cutting efficiency, people must first know the reasons for the low cutting efficiency of the wire saw, mainly as follows:

1: The most important reason for the low cutting efficiency in the wire saw cutting process is the poor diamond beads opening. There are three specific performances. The first is that the bond is smooth, not rough enough; The second is that diamond exposure height is low, and the blade tail is not obvious.The last is that diamonds have no corners and are ground flat. In the case of this beaded shape, it is likely that the stone will not be cut.

In order to help the blunt wire saw to re-diamond opening. There are some measurements.

Workers adjust the cutting area reasonably, and open the current as high as possible within the allowable range of the equipment. After that, workers need to reduce the line speed and cooling water volume to sharpen the diamond beads. It may take hours or more to get the diamond back out. In practice, a few meters of wire saw with a diameter of about 0.5mm smaller than normal diamond opening is connected to assist in cutting. And at the same time, a small amount of water and low linear speed can also help wire saw to re-open.

2: In the process of wire saw cutting, the diamond grade is inconsistent with the hardness of the actual cutting object. It is mainly manifested in the use of low-grade diamonds when cutting hard stone. During the collision between the diamond and the stone, the diamond is rapidly broken. The utilization rate of diamond is greatly reduced, which leads to the reduction of cutting efficiency. If high-grade diamonds are used for cutting soft stones, the diamonds will not be easily broken, but the diamonds will not be opened after being slowly ground, whose situation is similar to the first case.To improve this situation, it is necessary to select different grades of diamonds for cutting according to different stone hardness. Generally speaking, high-grade diamonds are required to cut hard materials. If the hardness is low, appropriately reducing the diamond grade is a practice that can improve the cutting efficiency.



3: The problem of the envelope is the problem of the cutting area. If the motor power of the wire saw is fixed during the cutting process, workers can adjust even reduce the envelope to improve the cutting efficiency. Simply put, if two wire saw machine has the same cutting efficiency, the larger the cutting area, the less the cutting pressure per unit stone during the cutting process.  Under the circumstance, the cutting efficiency is very low. However, if the flywheel is used to reduce the cutting surface, the cutting pressure can be increased, which will naturally improve the cutting efficiency.

The lifespan of the wire saw is also very important. At present, after research, there are some reasons for the low lifespan of wire saws. ①The bead formula does not match the cut stone; ② cutting process are improper, such as too low line speed, too small cooling water, etc.; ③ There is no guide wheel in the final cutting stage.

In fact, every factory would use diamond, powder, wire rope and other materials. And different combinations will have different cutting conditions. The wire saw would be better and better after constantly testing and constantly adapting to the actual situation of the stone.