Application of Large Diamond Circular Saw Blade in Stone Mining

I. Preface
As we all know, our stone resources predominate globally. In recent years, with the rapid development of the construction industry and the improvement of people's living standards, stone is increasingly favored by people with its unique natural properties and the demand of the market is increasing. At the same time, our stone processing technology has already approached the world advanced level, but the mining technology of stone is far behind that of developed countries.

In the past, there were several main mining methods in China, such as blasting, flame cutting and expanding agent. Generally, its mining methods have disadvantages such as low labor productivity, low yield, serious waste of resources and poor safety. In recent years, some enterprises have adopted diamond string bead rope saw, diamond chain saw and other mining methods.

 

Although good results have been achieved, large equipment investment and high mining costs still hinder large-scale use. How to improve the quality and efficiency of stone mining, minimize the damage to the environment, reduce the labor intensity of workers, etc., has become an urgent need to solve problems in stone waste mining in China. 

 

II. Cutting Principle
In view of the above situation, our scientific and technical personnel skillfully applied the cutting mechanism of plate in mining and achieved good results. Its basic principle is to lay tracks on the surface of the mine and drive super large diamond circular saw blades through the main engine. Ф 2000-4200mm) high speed rotation for on-rail cutting. Because of the advantages of less investment, high efficiency, safety, environmental protection, energy saving and low mining cost, this method is widely favored by mining enterprises.

III. Technical Requirements
Except for good precision of sawing machine, specification and quality of super large diamond circular saw blade are the key to this technology. It is well known that the size of the exploited waste is determined by the size of the net saw blade. At present, the board width required in the market is about 1.5m.

 

Therefore, the matching diamond circular saw blade must meet the specifications Ф At the same time, the field work environment such as mine work and flatness, cooling and chips removal, etc. are relatively slab cutting and the conditions are worse. Therefore, more stringent requirements are put forward for the manufacture of saw blade matrix.

 

Developed since 2003 according to market demand Ф The base of mine saw blade over 2300mm can be produced after several years of exploration. Ф 4200mm size large circular saw blade base.

According to the characteristics of mine cutting, there are three main technological breakthroughs:
1. Heat treatment method of products: There is no special equipment for heat treatment of such large size saw blade base in China at present. We adopt unique heat treatment process to solve the difficult heat treatment problem of large size and thin thickness saw base. The hardness can be well controlled in the range of HRC38+3, which improves the rigidity of saw blade base and increases the service life of products.

2. Processing method: Grinding of end face of saw blade base is also a difficult point in product processing. The manufacturer has developed a surface grinder and lathe, which solve this difficult problem skillfully. The thickness tolerance of the product can meet the requirements of national standards, and the static balance index of the product is greatly improved. At the same time, the fatigue life of the product is greatly improved by removing the oxidation and decarbonization layers on the material surface.

3. In view of the fact that it is difficult for the mine saw blade to remove chips during cutting, the manufacturer has also made bold exploration on the shape of the base body: by processing various holes in the appropriate parts of the base body of the saw blade, without affecting the overall strength of the saw blade, the cooling and chips removal efficiency has been improved, the service life of the blade has been extended, the energy has been reduced, and the exploitation time of waste material has been shortened.

 

IV. Comparison of economic and technical indexes with traditional mining methods
The application of new mining method improves resource utilization and exploitation speed. Due to the improvement of exploitation quality, the added value of products is increased accordingly. It reduces production costs, overcomes the disadvantages of traditional mining methods such as poor safety and serious environmental damage, and has great economic and social benefits. 

V. Requirements for Use
1. Preparation before installation
(1) The laying of the track of the saw requires that the sleepers be firmly and smoothly laid so as to avoid the shaking of the saw during cutting. The tolerance of the track parallelism of the saw should be less than 5mm and the tolerance of the level should be less than 2mm.

(2) In order to ensure the flatness and strength of the saw blade during cutting, the flange diameter for clamping the saw blade is > i280ram, and the flange roughness directly affects the end slip of the saw blade. Therefore, the user should check the flange accuracy before using it. Generally Ф The flange disc of 280mm has an unevenness of <0.05mm and is clean and free from debris and dirt.

(3) Always check the precision of the saw shaft to ensure that the radial runout of the main shaft is less than 0.03mm, so as to avoid the shaking of the saw blade during cutting and to influence the service life of the saw blade and the cutting quality of the material.

(4) The size of cooling water directly affects the cooling effect of the saw blade, chip removal ability and cutting life of the blade. Therefore it is recommended that Ф 2000 (or Ф 2200) Cooling water quantity (>1001/min) Ф 2800 (or Ф 3000) Cooling water (> 1601/rnin) and fully injected into the cutting seam of the saw blade.

2. Normative Use
Due to the high price of super large diamond net saw blades, standardized use can greatly increase the service life of products and reduce production costs, so standardized operation should be emphasized in the use of products.
(1) The new matrix should be idled for more than 30 minutes before its first use, so that the stress distribution of the saw blade matrix is more uniform under the action of centrifugal force during its first use.

(2) Conditional enterprises should cut the cutting edge before using the new saw blade, otherwise, when the new cutting head starts to use, the cutting amount is required to be less than l5mm/time and the walking speed is less than l000mm/min. Only when the diamond in the cutting head is completely cut, can the cutting amount be increased.

(3) When cutting normally, determine the feed quantity reasonably once according to the hardness of the cutting object, (b2000 (or Ф 2200) Size saw blades are controlled within 30-50mm/time. Ф 2800 (or Ф 3000) Saw blade should be controlled within 20-30mm/time, so as not to affect the cutting efficiency, the cutting process of shallow feed and fast moving blades should be carried out as far as possible to reduce the deformation of the saw blade base due to excessive normal force.

(4) In the cutting of a mine, the number of teeth that the saw blade participates in cutting increases greatly when cutting at both ends, so the resistance increases accordingly. Therefore, the point-to-point reciprocating cutting method should be adopted when cutting the knife. The amount of knife must not exceed 2 mm/time per point-to-move.

(5) During the use of saw blade, the state during cutting and the change of hardness of the cutting object should be strictly monitored. When the working surface protrudes too much, the cutting depth and travel speed should be adjusted in time.

VI. Conclusion
Mining waste material with super large diamond circular saw blade can reduce the mining cost by more than 20% and the yield of waste material can reach more than 90%. Mining method is simple, occupying small area, little damage to environment and regular waste exploitation. Therefore, it has great promotion value.