DEM modeling of a monowire cutting system

Monowire block cutting machines can be used for natural stone block squaring and slab cutting operations. The plants where the cutting operations are performed demand high product quality with minimum operational costs. The major parameters affecting the economy of the operation are the energy consumed and the wear induced on the diamond beads during the cutting operation. An efficient cutting operation can only be maintained by selecting proper cutting parameters. Therefore, cutting parameters should be clearly understood. Experimental studies and numerical modeling methods are significant in terms of identifying the energy consumption occurring during natural stone cutting with monowire. Experimental studies and numerical modeling using discrete element method were performed on Afyon White Marble. Experimental studies have been performed by using a specially designed, fully automatic monowire cutting machine, and numerical analyses were carried out by commercially available software called three-dimensional particle flow code (PFC3D). A discrete element model for the cutting operation was developed, and various numerical models were performed for different peripheral speeds and cutting speeds, while, at the same time, the actual cutting operations were being carried out in the laboratory. Finally, the data obtained from the experimental works were compared with the data from numerical modeling. A comparison indicates that the frictional energy values obtained by means of numerical modeling are in good agreement with the results of the laboratory measurements. This study clearly put forward the influences of effective parameters on monowire cutting operations in natural stone industry. Furthermore, it filled an important space in the literature about the use of monowire block squaring machines.     

Influence of physico-mechanical properties of Indian dimension stones on cutting rate of diamond wire saw

Cutting performance of diamond wire saw is a key factor influencing mine planning, production scheduling, and equipment selection for dimension stone quarries. It is normally measured in terms of cutting rate. Rock samples collected from various granite and marble quarries in India were tested in laboratory to determine their physico-mechanical properties. Cutting rate of diamond wire saw was measured in the field studies during the actual cutting process in quarries. Using these laboratory determined properties and the cutting rate, a multiple linear regression model has been developed to predict the cutting rate of diamond wire saw. Physico-mechanical properties of rocks determined in laboratory are used as independent variables and cutting rate as predictor variable in the regression model. The study indicates that the cutting rate increases with a decrease in most of the hardness and strength parameters of rock. The final model is tested for its goodness of fit indicating a significant linear relation between cutting rate and physico-mechanical properties, namely tensile strength, slake durability index, and Cerchar hardness index with regression coefficient of 94%. The resulting model can be used suitably for different types of hard to medium hard and soft dimension stones. The generalized model for estimating the cutting rate becomes a handy tool for mining engineers to work out operating efficiency, expenses, planning etc. of the dimension stone block cutting.     

Predicting the Performance of Chain Saw Machines Based on Shore Scleroscope Hardness

Shore hardness has been used to estimate several physical and mechanical properties of rocks over the last few decades. However, the number of researches correlating Shore hardness with rock cutting performance is quite limited. Also, rather limited researches have been carried out on predicting the performance of chain saw machines. This study differs from the previous investigations in the way that Shore hardness values (SH₁, SH₂, and deformation coefficient) are used to determine the field performance of chain saw machines. The measured Shore hardness values are correlated with the physical and mechanical properties of natural stone samples, cutting parameters (normal force, cutting force, and specific energy) obtained from linear cutting tests in unrelieved cutting mode, and areal net cutting rate of chain saw machines. Two empirical models developed previously are improved for the prediction of the areal net cutting rate of chain saw machines. The first model is based on a revised chain saw penetration index, which uses SH₁, machine weight, and useful arm cutting depth as predictors. The second model is based on the power consumed for only cutting the stone, arm thickness, and specific energy as a function of the deformation coefficient. While cutting force has a strong relationship with Shore hardness values, the normal force has a weak or moderate correlation. Uniaxial compressive strength, Cerchar abrasivity index, and density can also be predicted by Shore hardness values.     

Wear Performance of Saw Blades in Processing of Granitic Rocks and Development of Models for Wear Estimation

This study investigates the wear performance of diamond circular saw blades in cutting of granitic rocks. An alternative wear measuring method is developed to measure the reduced blade radius without taking the blade off the machine. The effect on and contribution to the specific wear rate (SWR) of each operating variable are determined, and the SWR is correlated with rock properties. Morphologies of wearing surfaces of segments and rocks are also evaluated using scanning electron microscopy (SEM). Depending on both operating variables and rock properties, prediction models are developed for estimation of the SWR. Results show that the SWR increases with an increase in the peripheral speed and the traverse speed, while it decreases with an increase in the cutting depth and the flow rate of the cooling fluid. The peripheral speed, and the microhardness and proportions of minerals such as quartz, plagioclase, and feldspar are statistically determined as the significant variables affecting the SWR. Finally, it is disclosed that models developed for estimation of SWR have great potential for practical applications.     

Predicting the production rate of diamond wire saw using statistical analysis

Performance prediction of diamond wire saws is important in the cost estimation and the planning of the stone quarries. An accurate estimation of sawability helps to make the planning of the rock cutting projects more efficient. In this paper, the performance prediction of diamond wire saws in cutting carbonate rocks was studied on 14 different carbonate rocks in stone quarries located in Iran. Rock samples were collected from the quarries for laboratory tests. Uniaxial compressive strength, Brazilian tensile strength, Schmidt hammer value, and Los Angeles abrasion were determined in the laboratory. Performance prediction was evaluated using simple and multiple regression analyses. Finally, a new model was proposed for predicting the production rate of diamond wire saw. It was concluded that the production rate of carbonate rock using diamond wire saw can reliably be estimated using the developed model.     

Prediction of sawing performance based on index properties of rocks

Performance analysis of all systems used in industrial production is very important subject in terms of capturing the low production cost. This subject is also important for choosing production methods in natural stone processing. Circular sawing is a commonly used method in natural stone processing. The preliminary prediction of circular sawing performance is very useful for stone producers. In this study, the prediction of sawing performance from some index properties of stones was conducted. The unit wear on diamond segments was evaluated as performance criteria. The statistical analysis was carried out, and this performance parameter was predicted from some index properties including cone indenter hardness, Shore hardness, Böhme surface abrasion, and brittleness. The most suitable prediction equation derived from regression analysis was selected. It was determined that this equation was statistically reliable for prediction of unit wear for natural stone processing.     

仿生高效切削齿试验研究

在仿生高效耐磨理论的指导下,以鼹鼠爪趾为仿生原型,引入了其经长期进化而具有的高效、耐磨的特性。选用CVD多晶金刚石为切削齿的切削单元,采用真空热压烧结工艺制备仿生高效切削齿,并将其与常规PDC齿、仿生PDC齿的耐磨性和切削效率进行对比试验,结果显示：仿生高效切削齿的耐磨性较常规PDC齿提高23%;切削效率较常规PDC齿提高1.49倍,较仿生PDC齿提高48%。初步证明了仿生高效切削齿工艺的可行性,为下一步高效切削钻头的研究奠定了坚实的基础。     

Surface Miners: Evaluation of the Production Rate and Cutting Performance Based on Rock Properties and Specific Energy

The purpose of this research was to evaluate the production rate (PR) and cutting performance of surface miners (SM) based on rock properties and specific energy (SE). We use data from equipment manufacturers and experimental data in this study and propose a new method and equations to determine both the PR and the cutting speed of SM. The unconfined compressive strength (UCS) of the rock, its abrasivity, and the machine’s engine power are the three most important factors influencing the PR. Moreover, the cutting depth, UCS, and engine power have a significant impact on the cutting speed. We propose a new method and equations to determine the energy required to cut a volume unit and a surface unit, i.e., specific energy, and establish the relationship between SE, UCS, and PR. The results of this study can be used by surface miner operators to evaluate the applicability of the machines to a specific mine site.     

Experimental and Statistical Evaluation of Cutting Methods in Relation to Specific Energy and Rock Properties

In a processing plant, natural stone can be cut by methods such as circular sawing (CS), frame sawing (FS), water jet cutting (WJC) and abrasive water jet cutting (AWJC). The efficiency of cutting systems can be compared using various parameters. In this study, the specific energy values were determined and compared to evaluate the efficiency of rock-cutting methods. Rock-cutting experiments were performed on 12 different types of rock samples using a circular sawing machine and an AWJC machine. The experimental results showed that the specific energy values in AWJC were generally higher than in CS. In addition, the relationships between specific energy values and rock properties were explained in this study. The Shore hardness and abrasion resistance were found to be strongly related to the specific energy values, and according to these parameters prediction charts of specific energy values were created.     

水冷式工频大电流烧结机的研制

随着我国石材工业的发展，为满足石材加工设备的大量需求，研制了水冷式工频大电流烧结机。该机采用水冷式变压器（目前国内其它烧结机为风冷式变压器）。副边水冷绕组与原绕组相互叠合，达到初次级绕组同时冷却效果。有效地降低了次级线圈内阻，减少损耗，使其发挥最大效率。并可以连续方便地调整加热功率，实现温度调节、温度测量、保温自动控制和保温时间控制，以满足金刚石石材切割工具烧结的不同工艺要求。在推向市场的几年中，证明该机具有加热功率大、体积小、升温快，控制温度准确、操作简便和成本低的特点。是目前国内烧结金刚石工具较先进的设备。该机在十几个省市推广应用中，获得了较好的经济效益和社会效益，同时也推动了我国金刚石制品行业的发展。     

Development of Predictive Models for the Specific Energy of Circular Diamond Sawblades in the Sawing of Granitic Rocks

This paper presents an experimental study on the sawing of granitic rocks by circular diamond sawblades. The influence of the operating variables and rock properties on the specific energy were initially investigated and analyzed. To determine the most significant operating variables and rock properties influencing the specific energy, statistical analyses were then employed and the models were built for the estimation of specific energy depending on the operating variables and the rock properties. Moreover, the derived models were validated through statistical tests such as the determination coefficient, t-test, F-test, and residuals. The results indicated that the specific energy decreased with the decreasing of peripheral speed and the increasing of traverse speed, cutting depth, and flow rate of cooling fluid, respectively. It was concluded that, rather than the physico-mechanical properties, the mineralogical properties were the dominant rock properties affecting the specific energy. Additionally, the peripheral speed was statistically determined as the most significant operating variable affecting the specific energy. The peripheral speed was followed by the cutting depth, traverse speed, and flow rate of cooling fluid with respect to their level of significance on the specific energy. Furthermore, the model results revealed that the developed models have high potentials as a guidance for practical applications.     

Investigation on the usage of different rock aggregates as abrasive materials in natural stone aging process

The process of giving an antique look, a worn and “old” appearance, to natural stone surfaces, which can be observed by abrasion in natural ways through a long time, is called artificial aging. Natural stone processing facilities that involve mass production usually prefer vibration aging machines. This study examines the utilization of various rock aggregates and abrasive residuals instead of synthetic abrasives used in aging machines. Natural stone samples with different properties were aged in a vibration aging machine using andesite, granite, sandstone, pebble stone, abrasive stone residuals, and ceramic abrasives. At the end of the study, the aging performance of different rocks was determined; granite was found to be the most effective. Rock aggregates were ranked in terms of their abrasiveness (aging) performance, from the most effective to the least effective as: granite, ceramic abrasive, sandstone, andesite, pebble stone, and abrasive stone residuals. It was observed that rock aggregates can be used in the aging process instead of synthetic ceramic abrasives, with desired performance.     

Prediction of the sawing quality of Marmarit stones using the capability of artificial neural network

The sawing rate is one of the most significant and effective parameters in extracting building stones via diamond wire sawing. This parameter designates the capability of diamond wire sawing for sawing different stones; in addition, the parameter gives rise to economical considerations for quarry designers. In this study, the existent relations between stone geotechnical parameters and the sawing rate of stones via diamond wire sawing were analyzed using regression and correlation coefficient as well as the collected data from Marmarit stone quarries. Moreover, we estimated the sawing rate of Marmarit using the dimensional stone rock mass rating (DSRMR); upon comparison of the data obtained from DSRMR our pre‐collected data on quarries, we did not gain satisfactory results from DSRMR, hence we used artificial neural network (ANN). The results showed that the percentage of Silica, the coefficient of water absorption, the uniaxial compressive strength (UCS), and abrasive hardness are the proper parameters for creating the ANN. Discontinuities have the least effects possible on diamond wire sawing. Having given the training possibility of the ANN, and its ability to evaluate relations among input parameters, the ANN, which was being trained with Marmarit's traits, was an accurate network for estimating diamond wire sawing in Marmarit quarries, although it could not generalize this network for other stones such as Chini and Crystal. Copyright © 2011 John Wiley & Sons, Ltd.     

Grinding of mineral mixtures in high-pressure grinding rolls

Attempts at improving comminution machines generally have been directed towards increasing the performance efficiency, particularly increasing throughput rate and decreasing energy consumption. The latest and most successful new comminution technology has been the high-pressure grinding rolls (HPGR), which have proved to be highly efficient in energy consumption and to have a relatively high throughput rate at low steel consumption. Already used extensively in cement plants worldwide, the first HPGRs in the mineral industry were installed in plants processing diamond ores. They are now finding their way into the large-scale base-metal mining industry. Since feed constituents in natural ores vary in their physical properties such as hardness, plasticity and brittleness, the present paper is concerned with an investigation of the behavior of a heterogeneous feed as it passes through the HPGR. The effect of feed composition on operational parameters, the energy efficiency of comminution, and energy distribution among the feed components is addressed. Mineral particles with high hardness act as energy transfer agents in the roll gap and enhance the grinding of softer mineral particles in a mixed feed.     

Predicting the Building Stone Cutting Rate Based on Rock Properties and Device Pullback Amperage in Quarries Using M5P Model Tree

One of the key parameters that affect the selection of equipment and the cost estimation of dimension stone quarries is the rock cutting rate or production rate. In this study, the M5P tree algorithm is used to determine the relationship between the hard rock sawability and its factors especially the physical and mechanical characteristics of rock. To achieve the research goal, a variety of eleven types of hard dimension stone were selected and nine major physical and mechanical characteristics of rock including uniaxial compressive strength, Young’s modulus, Brazilian tensile strength, equivalent quarts content, grain size, Mohs hardness, point load test, density and P-wave velocity of these samples were evaluated. The cutting rate of diamond wire for all of the Workpiece was measured at different pullback amperage with a fully instrumented cutting platform in laboratory. All operational parameters of cutting process were entirely controlled. Thus, a database containing 99 datasets was provided and it has been used for analyses. The obtained results from the pruned and unpruned tree models showed a significant relationship between cutting rate and its factors. In the end, the results of M5P tree method were compared with statistical analyses (i.e., linear and nonlinear regression). The coefficient of determination be equal with 0.92, 0.86, 0.77 and 0.63 for unpruned tree, pruned tree, linear and nonlinear regression method respectively. This comparison showed that the both method of M5P tree technique have a better performance in predicting the cutting rate rather than the statistical regression methods.     

孕镶金刚石钻头磨损机理研究

孕镶金刚石钻头通过钻头胎体的持续磨损实现金刚石的自锐和高效破岩。因此,研究金刚石钻头磨损的影响因素及其影响程度和影响机理,对孕镶金刚石钻头的设计和使用非常重要。本次研究探讨了岩石物理力学性质、钻头胎体性能和钻进工艺参数等因素对孕镶金刚石钻头磨损过程和磨损机理的影响。分析表明,对钻头磨损最为显著的影响因素是岩石中的硬质颗粒导致的磨粒磨损,其次是钻头胎体与岩粉之间的粘着磨损,以及冲洗液中岩粉颗粒导致的冲蚀磨损。在此基础上,以不同硬度的钻头胎体摩擦磨损试验结果为例,探讨了钻头胎体性能及其内部硬质点对钻头磨损的影响机理。该研究成果可为科学设计与合理使用孕镶金刚石钻头提供依据。     

Roadheader performance prediction using genetic programming (GP) and gene expression programming (GEP) techniques

Roadheading machines play a vital role in excavation operation in tunneling and mining industries notably when selective mining is required. Roadheaders are more effective in soft to medium rock formations due to a higher cutting rate in such strata. A precise prediction of machine’s performance is a crucial issue, as it has considerable effects on excavation planning, project’s cost estimation, machine specification selection as well as safety of the project. In this research, a database of machine performance and some geomechanical parameters of rock formations from Tabas coal mine project, the largest and fully mechanized coal mine in Iran, has been established, including instantaneous cutting rate (ICR), uniaxial compressive strength, Brazilian tensile strength, rock quality designation, influence of discontinuity orientation (Alpha angle) and specific energy. Afterward, the parameters were analyzed through genetic programming (GP) and gene expression programming (GEP) approaches to yield more accurate models to predict the performance of roadheaders. As statistical indices, coefficient of determination, root mean square error and variance account were used to evaluate the efficiency of the developed models. According to the obtained results, it was observed that developed models can effectively be implemented for prediction of roadheader performance. Moreover, it was concluded that performance of the GEP model is better than the GP model. A high conformity was observed between predicted and measured roadheader ICR for GEP model.     

Laboratory investigations on rotary diamond drilling

Extensive laboratory drilling investigations were conducted on a wide variety of rocks to study the inter-dependence of machine as well as rock parameters on the performance of the drilling operation. Detailed physical and mechanical properties of all the rock types were determined to study the influence of the rock properties on the drilling performance. The effect of PEO (poly-ethylene-oxide) added to the drilling water was also studied. Slake durability tests were conducted in plain water as well as a PEO mixed water medium to observe the effects of PEO on the surface properties of the rock. An attempt is also made to understand the different modes of wear of impregnated diamond bits in the rotary drilling operation.     

提高金刚石粘结强度的技术及其应用

真空沉积渗覆法使金刚石表面形成金属碳化物过渡层和化学镀法使金刚石表面生成有良好湿润性的低熔点金刚石过镀层,改善粘结材料对金刚石的粘结状态,提高了粘结强度.通过采用相应的粘结材料和烧结工艺,将金属化金刚石成功地应用于石材切割锯片,取得了提高锯片效率30～100%,寿命延长20%以上的效果.     

仿生孕镶金刚石钻头在漠河冻土区天然气水合物勘探钻进中的应用

仿生孕镶金刚石钻头具有高效、耐磨的特点,符合漠河天然气水合物勘探的要求及漠河钻探施工现场的条件。介绍了符合漠河地层特点的仿生孕镶金刚石钻头的设计与制造。同时对效果不理想的钻头的钻进情况进行了分析,提出了评价钻头性能时需要综合分析,从而客观、真实地反映钻头的实际钻进能力。漠河天然气水合物MK-2科学钻探试验井的钻进结果表明,仿生孕镶金刚石钻头的寿命比普通孕镶金刚石钻头长73%,钻速比普通孕镶金刚石钻头高22%。