Abstract
Diamond wires are high-speed, efficient and cost-effective stone cutting tools used both in quarries, to obtain large stone blocks, and in block-processing plants, to shape ornamental stones. Diamond wires are generally composed by a wire rope with evenly spaced diamond beads fixed by a polymer or rubber coating. A numerical model of the diamond wire was developed in Abaqus™ software aiming to study the damage and failure of the steel wire during the cutting process. The model is intended to support the development of this component with enhanced durability and damage resistance. Previously in this work, a detailed three-dimensional (3D) and numerical model of a 7x7 wire rope was created, followed by experimental validation. The diamond wire model was then based on the wire rope model, with the addition of the polymer coating and the diamond beads. The developed diamond wire model presents an error smaller than 6% relative to the experimental tensile test, corresponding to a valid representation of the component. This model has practical significance for the mechanical evaluation of the diamond wire, supporting further developments, with special focus on its design and manufacturing, to achieve longer service life.
Highlights
Diamond wires are commonly used as a cutting tool for the extraction of large stone blocks at quarries and/or to shape ornamental stones in block processing plants
This work aims to develop a numerical model of the diamond wire that correctly represents its stress/strain response during the cutting operation, applying the wire rope numerical simulation methods and the knowledge from the forces applied to the diamond wire and its behaviour on a multi-wire sawing machine
Different loading cases were applied to the diamond wire model to analyse the influence of the cutting parameters
Summary
Diamond wires are commonly used as a cutting tool for the extraction of large stone blocks at quarries and/or to shape ornamental stones in block processing plants. It is the most efficient tool for stone cutting, and it already has a long history in the processing of limestone. Diamond beads allowed the application of wires in harder stones, as granite. These developments impose a higher load requirement on the diamond wire, leading to premature failures [1]. Diamond wires consist essentially of a high-strength wire rope, with diamond beads threaded on it. The diamond wire contains between 30 and 40 beads per meter, and it is pre-twisted during its production, which induces an axial rotation during the cutting operation
Sign-in/Register to view highlights & summary 
Published Version (
Free)
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call