Description of large size big diamond circular saw blade
Stone block cutting refers to the stone material with certain shape and specification mined from quarry, which is processed into slab by using different cutting blades. We normally using large size big diamond circular saw blade or band saw blade to cut stone block into slab. The large size big diamond circular saw blade is suitable for cutting both marble and granite, while band saw blade is only suitable for cutting marble blocks. Generally, large size big diameter saw blade is used for sawing of block materials, and diameter of the saw blade is 1600-4500mm, which is suitable for different materials and processing equipment. Diamond saw blade can be divided into single blade cutting and multi-blade cutting according to the number of saw blades. The diameter of the saw blades used for multiple blades can be the same or different. According to the sawing mode, it can be divided into single direction sawing and double direction sawing. Two direction sawing is to complete vertical and horizontal sawing at the same time.
Cutting parameters of large size big diamond circular saw blade
The large diamond circular saw blade for cutting block material is welded with diamond segments and the blade body. The segment adopts a three-layer structure with trapezoidal cross-section, which can eliminate side friction and lateral deviation, improve the guiding performance of segments, and improve the machining accuracy and quality. Below is a pictures to show cutting parameter of large size diamond circular saw blade.
|Power of motor（kW）||35 〜45||45 〜60||55 〜75||75 〜100||75 〜100|
|Water consumption（L/min）||60 〜70||70 〜80||80 〜100||80 〜120||80 〜120|
Large Size big diamond circular saw blade Axial deviation
Large Size big diamond circular saw blade Radial deviation
|Table Guide Rail（mm）||0.15||0.20||0.25||0.30||0.30|
Service life of large size big diamond saw blade is mainly affected by processing parameters and stone properties. The processing parameters mainly include the spindle speed, feed speed, feed depth and cooling water flow. Stone parameters mainly include stone hardness, stone composition, etc. Below tables show the relevant parameters affecting the processing of diamond saw blade.
Spindle speed of large size big diamond circular saw blade（r/m）
|Linear Cutting speed（25m/s）||300||240||180||160||140|
|Linear Cutting Speed（30 m/s）||360||290||210||190||160|
|Linear Cutting Speed（35 m/s）||420||330||250||220||190|
|Linear Cutting Speed（40 m/s）||480||380||280||250||220|
|Linear Cutting Speed（45 m/s）||540||430||320||290||250|
|Linear Cuting Speed（50 m/s）||600||480||350||320||70|
|Linear Cutting speed（60m/s）||720||570||420||380||330|
Parameters of saw blade for sawing different stone hardness
|Grade of stone hardness||1||2||3||4||5|
|Feeding Speed（mm）||10 〜15||8〜12||6〜]0||5〜8||4〜6|
|Feeding Speed（m/min）||2.5 〜3.5||2.5 〜3.5||2.5 〜3.5||2.5 〜3.5||2.5 〜3.5|
|Linear Speed（m/s）||24 〜32||24 〜32||24 〜32||24 〜32||24 〜32|
|Cutting Efficicncy（cm/min）||250〜525||200 〜420||150〜350||125〜280||100〜210|
Stone blocks are divided into different grades according to the hardness of the stone. Different sizes of diamond segments are used to cut different hardness of block. Diamond segments should have a balanced proportion in width of substrate to ensure smooth discharge of the processed material and the uniform wear of diamond segment, so as to avoid matrix being clamped by block material. The cutting speed of thin matrix diamond segment is fast, but its service life is short. The cutting speed of thick matrix diamond segment is slow, but its service life is long. This is mainly due to the smaller contact area between the thinner diamond segment and processed material, and the smaller resistance when processing stone. According to different hardness of stone and mechanical properties of diamond segment, the sizes of different diamond segment are listed, as shown in below table.
Diamond segments which are suitable for cutting granite block
Diamond segments which are suitable for cutting marble block
Diamond segments which are suitable for cutting limestone and sandstone
Diamond segment is the main component of large size big diamond circular saw blade. The diamond segment can be trapezoidal or rectangular, with both sides higher than the substrate and distributed between two water tanks. It is not only conducive to cooling, chip holding and chip removal, but also can overcome shortcomings of common trapezoidal blade, such as damaging stone plate due to line contact. Below two tables respectively list the parameters of large size big diamond circular saw blade and segment for cutting various granite and marble block.
Large size big diamond circular saw blade and segment for granite block
|Bladediameter（mm）||Segment size（LxWxH）（mm）||Thickness（mm）||Segment quantity|
Large size big diamond circular saw blade and segment for granite block
|Blade Diameter(mm)||Segment size (LxWxH)||(mm)||Thickness|
Welding of large size big diamond circular saw blade
There are two kinds of welding of diamond segment and steel matrix, namely vacuum brazing and laser welding.
Vacuum Brazing: the diamond segment is placed in center of the width of substrate, and silver copper alloy sheet is placed between diamond segment and substrate, and high frequency induction coil is used for heating and curing. This kind of saw blade can only be used for wet cutting, but not for dry cutting.
Laser welding: laser beam is used to weld the diamond segment on substrate, which makes diamond segment and substrate have strong welding strength. Laser welding blades can be used for wet and dry cutting. Laser welding is a new technology and new process researched in recent years. This method has great safety, but it is only suitable for welding saw blade with diameter less than 600mm.
When the diamond segment is welded to the substrate, each segment should be subjected to bending test to ensure the segment is firmly welded with the substrate. At the same time, the stress test of each saw blade is carried out to ensure there is no deflection when rotating. The stress test is usually done manually by technicians with test experience. Each large size blade should be sharpened to shorten the auxiliary time. The influence of processing parameters on the saw blade should be considered in the use process. General soft bond has high cutting efficiency, but short service life, while hard bond cutting efficiency is low, but long life.
How to choose a large size big diamond circular saw blade
The selection of saw blade must correspond to the hardness and wear resistance of the processed material. The type of saw blade is determined by these two factors. Material properties determine the service life of large size diamond circular saw blade. If we use a marble saw blade to cut sandstone material, the diamond segments will be completely worn out after cutting several square meters. Although sandstone is softer than marble, it has greater wear resistance than marble. The use of diamond saw blade is affected by many factors, including processing parameters, equipment parameters, etc.
Selection of cutting parameter
Cutting speed is a very important processing parameter. It is necessary to adjust the cutting speed to match the cutting efficiency.
H5 Cutting Depth. The cutting depth and feed rate should be combined and corresponding to the machining efficiency. The cutting depth should be selected according to the hardness of the stone and the type of tool.
The feed rate depends on the cutting depth. A large feed rate corresponds to a small cutting depth and a sharp diamond tool, while a low feed rate corresponds to a large cutting depth and a less sharp diamond tool.
Selection of equipment parameter
Circular speed of saw blade
The selection of circular speed of saw blade should consider not only the hardness and wear resistance of the material, but also the feed speed. The feed rate affects the cutting speed and tool life, so it is necessary to match the circumferential speed with the material to be processed. The service life of diamond saw blade is greatly affected by the circular speed of saw blade. Below is a table to show circular speed of large size diamond saw blade with different stone materials. We can see from the table that the greater the hardness of stone, the smaller the linear speed of saw blade. For a given saw blade, the high speed and high hardness saw blade can prolong the service life, the low speed and low hardness saw blade can shorten the service life.
|Stone Material||Speed(m/s)||Power(100〜130 kW)||Power(120-160 kW)|
|High quartz content granite||25 〜30||–||–|
|Middle quartz content granite||30 〜40||–||–|
The flow rate of cooling water also has a certain impact on the efficiency and service life of large size big diamond circular saw blade. Therefore, it is recommended to use cooling water with high flow rate.
Power of cutting efficiency
The cutting power is mainly determined by the diameter of diamond saw blade and the type of material to be processed
Storage of large size big diamond circular saw blade
When the large size big diamond saw blade is not in use, the diamond saw blade should be placed on a flat place or hung up with a central hole. Do not lean the saw blade against the wall to avoid deformation of the saw blade.
Installation and inspection of large size big diamond saw blade
Installation of large size big diamond circular saw blade
Pay attention to the following matters before installing a large size big diamond circular saw blade.
- Cleaningthe rust and oil on the spindle and flange, all surfaces must be cleaned with fine corundum sandpaper.
- If there are deformation and burron flange edge of large diamond saw blade, use a fine knife to trim them.
- The saw blade must not be placed on the thread of the spindle to avoid damaging the thread of the spindle.
- The saw blade must be installed according to the rotary arrow marked on the saw blade.
- When the large diamond saw blade is frequently loaded and unloaded, the saw blade and flange shall be repositioned and the position of the saw blade shall be checked.
- The diameter of the main shaft hole of the saw blade must be equal to the diameter of the main shaft hole, and the tolerance should be within 0.01 mm to avoid the radial movement of the saw blade. If the diameter of the main shaft of the saw blade is too large, steel washer with the same thickness as the saw blade must be added. If the diameter of the main shaft of the saw blade is too small, the saw blade must be returned to the tool factory and replaced with a suitable saw blade. The diameter of the main shaft of the saw blade should not be enlarged.
- The hole diameter of the flange plate is determined by the diameter of the saw blade and has a small diameter.
Inspection of large size big diamond circular saw blade
- The radial error detection of the shaft uses the radial instrument to detect whether the radial error of the spindle is within the allowable range.
- Use radial instrument to detect the radial error detection of the shaft to check if the radial error of the spindle is within the allowable range.
- Use a comparator to check whether the side runout of flange exceeds the error range.
- Check whether the spindle is vertical to the working table with a level instrument.
- Check whether the side run out error of saw blade is within the range with detection instrument. If the side error is more than twice of the allowable value, it means that the saw blade is dangerous and cannot be used.
- For the sawing motion, the movement direction of the table should be in a plane with the saw blade. In order to detect the parallelism, use the tester to measure.
Large size big diamond circular saw blade with two ways cutting
The large saw blade of diamond two-way cutting machine is mainly used to cut small block materials. The saw blade is mainly composed of vertical saw blade and horizontal saw blade, which can complete vertical cutting and horizontal cutting of stone at the same time. These saw blades can process different stones economically and quickly and are suitable for different equipment.
Segments on diamond saw blade with diameter of 800 series is formed by welding. The diamond segments adopt three-layer structure, and cross-section of the segment is trapezoidal, which can eliminate side friction and lateral deviation, improve guiding function of the diamond segment, maintain the profile of the segment and improve machining quality.
Specifications of two ways block cutting machine
Specifications of horizontal Cutting Machine
Multi-Blades for block cutting
In order to obtain better cutting efficiency, a number of diamond saw blades are installed on a main shaft. And we can get a multi slabs with only one time cutting
Multi saw blade for granite cutting.
Granite cutting Multi diamond circular saw blade is mainly used for cutting granite raw materials. It has the characteristics of high cutting efficiency, high cutting precision, long service life, high flatness and power saving. During machining, 20 ~ 30 pieces of diamond saw blades with same diameter are assembled into a group and installed on the main shaft of the saw. It is mainly used for four column combined saw machine.
Specifications of multi blade diamond circular saw blades
|Diameter（mm）||Segment（LXWXH）（mm）||Segment Quantity||Blade Quantity|
Ultra-thin multi blade circular cutting saw blade
The ultra-thin diamond combined saw blade for granite cutting is developed on the basis of the original group saw. The thickness of the saw blade can reach 3 mm. The substrate of saw blade is 75Crl steel, which has good mechanical properties after heat treatment. Hardness HRC (43 ± 1.5), thickness deviation (4.5 0.05 mm), end face circle run out 0.4 mm, flatness 0.6 mm, center hole deviation (± 0.054 mm).
The combination of saw blades is ladder type, the number of blades is 4, and the diameter of saw blades is respectively 1 600 mm, 1 200 mm, < 900 mm and 600 mm. The number of saw blades is 96, 90, 84 and 72 teeth respectively. The cross section of the cutter head adopts trapezoidal structure and sandwich mode to ensure the sharpness of the saw blade.
This type of saw blade usually uses 4 ~ 5 saws of different sizes on one cutting machine, which is quite suitable for cutting medium hard and soft stones and can save energy. Hard stone can also be cut, but the operator must have rich operation experience. Compared with other cutting methods, this kind of combined saw blade can produce more slabs and save cost of diamond segment.
Specifications of ultra-thin multi blade diamond saw blade
|Diameter（mm）||segment（LXWXH）（mm）||Segment Quantity||Blade Quantity|
|800||24X4.0/4.5/5.0X12/15||66||3 or 4|
|1 000||24X4.0/4.5/5.0X12/15||70||3 or 4|