Understanding the wear mechanisms of diamond circular saw blades during machining hard rocks

Abstract

Hard rock, prized for its exceptional resistance to corrosion and pollution, is extensively utilized in construction and transportation. However, its high hardness poses a significant challenge to the limited lifespan of diamond tools. This study delves into the wear mechanisms affecting diamond circular saw blades during hard rock machining. Initially, the dynamic behavior of saw blades was analyzed to uncover the wear and breakage characteristics of diamond segments. Through systematic characterization, the wear mechanisms and chemical element deposition were elucidated. The findings reveal that the front segment gradually loses sharpness due to primary rock impact, primarily experiencing bond wear, abrasive wear, and pull-out, while the rear segment encounters mainly abrasive and bond wear. Fresh and whole diamonds are approximately 45% with around 25% exhibiting macro-fractures and pull-out at the front segment, whereas the rear segment comprises over 50% fresh diamonds, with less than 20% showing macro-fractures and pull-out. Side edges predominantly undergo abrasive wear, bond wear, and pull-out or breakage, while medium edges experience abrasive wear, bond layer wear, and wear equalization. The rock is removed in a brittle and partly elastic-plastic manner. Through a comprehensive investigation, the wear process of diamond segments was clarified, attributing diamond wear to vibration shock, fatigue wear, and grinding heat, while bond wear factors include debris hardening point, fatigue wear, and chemical erosion. These systematic findings shed light on the wear characteristics of diamond segments, serving as a crucial theoretical guide for the material design of diamond segments for machining hard rocks.