Analysis of bead wear in diamond wire sawing considering the rock properties and production rate

Predicting the wear rate of diamond beads in the diamond wire sawing process is one of the most important factors in the optimized design and cost estimation of quarrying. This paper aims to predict the wear rate of diamond beads as one of the principal performance criteria in dimension stone quarrying. Saw operating parameters and mechanical and physical properties of rock are the most effective factors on diamond bead wear. In the same working conditions (at constant operating parameters), the wear rate of diamond wire saw is strongly affected by the production rate, and the characteristics of rock. In this study, the uniaxial compressive strength, Schmiazek abrasivity factor, Mohs hardness, and Young’s modulus were selected as the main physical and mechanical properties of rock. The 11 types of igneous rocks were cut in the laboratory using a diamond wire saw and a fully instrumented cutting platform. During the cutting process, the wear rate of diamond beads were determined after each cutting test. The wear rate of diamond bead and rock characteristics were evaluated using simple and multiple curvilinear regression analysis, and prediction models were developed. The developed models were validated by considering the t-test, F-test, correlation coefficient and the plots of predicted versus actual values. The results indicated that the wear rate of diamond beads can be reliably predicted using the developed model.