Investigation of Cutting Rate of Diamond Wire Saw Machine Using Numerical Modeling

Cutting rate in diamond wire method is one of the most important criteria in evaluation process of this method. In this research, using numerical modeling and PFC3D software, the effect of controllable parameters on the cutting rate have been investigated, the optimal values of these parameters have been determined, and finally an empirical relationship between these parameters and the cutting rate of diamond wire has been developed. These parameters include the diamond wire peripheral speed, number of beads per unit length of the wire, cutting machine pullback amperage and beads diameter. Numerical simulation and its validation are based on experiments performed on a granite stone sample. Numerical modeling results show that the wire peripheral speed and pullback amperage are directly related to the cutting rate. Optimal values for these parameters are the highest possible value. In other words, by technology advancement and ability to increase values of these parameters in wire cutting machines, higher cutting rates can be achieved. Evaluation of the number of beads per unit length of wire shows that by increasing it to 36 beads, the cutting rate increases, but with further increasing, cutting rate remains almost constant. Therefore, 36 beads per length unit of wire is the optimal value. Evaluation of the effect of the bead diameter on the cutting rate shows that the maximum cutting rate occurs when the bead diameter is equal to 1 cm. By further increasing of this parameter, cutting rate decreases. Therefore, optimal value of bead diameter is 1 cm. By comparing the effects of the mentioned parameters on the cutting rate, machine pullback amperage can be expressed as the most effective parameter. Finally, using multivariate regression, an experimental relation between the cutting rate and the mentioned parameters with a correlation coefficient of 0.98 has been achieved. This relation can be used to predict and improve the performance of diamond wire saw in granite stones’ cutting.