Assessment of the wear of diamond beads in the cutting of different rock types by the ridge regression

doi:10.1016/S0924-0136(02)00429-6

Journal of Materials Processing Technology

Volume 127, Issue 3, 3 October 2002, Pages 392-400

https://doi.org/10.1016/S0924-0136(02)00429-6 Get rights and content

Abstract

In this study, diamond wire cutting operation is performed on three different rock types. The operation is examined in three different groups in consideration with the mineralogical–petrographical properties of rocks; Ankara-Çubuk andesite group, Uşak White, Kozağaç White, Milas Leylak, Afyon Kaymak marbles group and Yeşilova Beige, Sivrihisar Limestone group. Statistical wear rate models are developed by using the results obtained from the operations and laboratory experiments by using ridge regression method. The rock type was also considered in the models developed for horizontal and vertical cutting separately, and the results are tested statistically. The statistical models developed were determined to be in accordance with the field data and could be used easily in practice.

Introduction

Diamond wire cutting machines have been used in marble industry since 1985 and have affected the production rate and efficiency considerably. Despite the common use of these machines in the world, there is a lack of investigation about improvement of the working conditions together with increasing efficiency. Moreover, there are no studies on factors affecting the wear of diamond beads and estimation of wear for different types of rocks prior to cutting.

Statistical model equations established for different rock types separately do not show the effect of the rock type. If the effect of the rock type on the wear of diamond beads is known or the existence of the effect is considered as premonition, this effect should be included in a model as a dummy variable. When different equations are established for different rock types, the effect of the rock type cannot be shown.

The wear rate of the diamond bead is a major parameter which affects operating cost in a marble quarry and this makes it very important to predict the wear rate on the beads of diamond wire before cutting the block in diamond wire cutting method [1].

Besides, the prediction of the wear of the bead helps the estimation of the life of the diamond wire and consequently ordering time of a new wire. Therefore, developing statistical model equations with the assistance of experimental studies performed in the laboratory and results obtained from the diamond wire cutting operations in the quarry production units, is an important issue.

The effect of rock types on the wear of bead is obvious and so far no study has considered this effect in detail. In fact, assembling and evaluation of all rock types in a single model will lead to misinterpretations. Therefore, it is necessary to develop a model containing the effects of all rock types.

The aim of this study is to develop and test the validity of statistical wear models for different rock types by using the ridge regression separately for horizontal and vertical cutting types. For this purpose, diamond wire cutting studies have been performed in seven different marble quarries for three different rock types. All of these studies have been performed separately in 31 cutting processes as vertical and horizontal cuttings.

Section snippets

Diamond wire cutting method

The principle behind diamond wire cutting involves pulling a spinning, continuous loop of wire mounted with diamond bonded steel beads through the stone to provide the cutting action. Through the combination of the spinning wire and the constant pulling force on the wire, a path is cut through the stone. In marble quarrying through diamond wire cutting, the initial step for making a vertical cut is to drill two holes, one vertical and one horizontal, which intersect at a 90° angle. The diamond

Field and laboratory studies

Parallel to the purpose of this study, the only and first diamond wire cutting operation (vertical and horizontal) in andesites and the applications of diamond wire cutting in real marbles and limestone (vertical and horizontal) have been performed at quarries in seven areas in Turkey. A location map of the investigated marble quarry areas is shown in Fig. 4. Cutting rates, wearing on beads, energy and water consumption for any rock types from 31 different locality have been recorded. The

Statistical analysis

In order to facilitate the analysis and interpretation of the results obtained by field and laboratory studies, the dependent variable is denoted by Y (wear rate) and independent variables by X₁ (specific gravity), X₂ (water adsorption), X₃ (apparent porosity), X₄ (uniaxial compression strength), X₅ (tensile strength), X₆ (point load strength), X₇ (shore scleroscope hardness), X₈ (NCB cone-indenter hardness), X₉ (Schmidt hardness), X₁₀ (modulus of elasticity), X₁₁ (Los Angeles abrasion strength

Conclusions

In this study, the regression models related with the wear of beads are developed for rocks which have different physical, chemical, mechanical and mineralogical–petrographical properties. These models are developed for horizontal and vertical cutting separately. The vertical and horizontal wear rate models yield similar results. Therefore, it is appropriate to use only one of these models. In these models, there are a number of variables, which can be determined (measured) in laboratory easily

References (11)

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