Granite Sawing Research Articles

Effect of process parameters on characteristics and pore structure of foam ceramics prepared from granite sawing dust

Foam ceramics made from solid waste have recently attracted considerable interest because of their environmentally friendly and sustainable properties. This study examines the manufacturing of foam ceramics through the direct sintering of granite sawing dust. An orthogonal experimental design was employed to explore the impact of the foaming-agent content, sintering temperature, holding time, and moulding pressure on the characteristics of foam ceramics. The experimental and analytical results show that under the given conditions involving a foaming agent content of 0.8 wt%, a sintering temperature of 1200 °C, a holding time of 30 min and a moulding pressure of 5 MPa, the produced foam ceramics have excellent properties. These included a bulk density of 0.892 g/cm³, water absorption of 0.130 %, porosity of 59.67 %, high compressive strength of 10.721 MPa, and thermal conductivity of 0.247 W/(m·K). Analysis of the pore structure revealed that the samples had an evenly distributed and sealed pore structure, which effectively increased the porosity and bulk density. This study effectively demonstrates the viability of producing porous ceramics from granite sawing dust, presenting a green and economically sustainable method for waste management and the creation of high-functioning materials. These findings offer promising prospects for the greater implementation of granite waste in the construction sector.

Preparation of municipal solid waste incineration fly ash/ granite sawing mud ceramsite and the morphological transformation and migration properties of chlorine

Municipal solid waste incineration (MSWI) fly ash is a hazardous waste containing high chlorine and harmful substances generated during the waste incineration disposal, and its resource utilization has a positive effect on reducing environmental pollution. In this study, the feasibility of preparing lightweight MSWI fly ash/granite sawing mud ceramsite (MG ceramsite) was investigated by evaluating the influence of Al2O3 addition, MSWI fly ash content and sintering temperature on the ceramsite properties. The microstructure of MG ceramsite was investigated by using SEM, the chlorine morphological transformation and migration behaviors were simultaneously explored by using the tube furnace experiment, XRD and XRF analyses. The experimental results show that the maximum MSWI fly ash content is about 30 wt%∼35 wt%, with the Al2O3 addition of at least 10 %. By controlling the MSWI fly ash content of 30 wt%, MG ceramsite can be obtained with bulk density of 986 kg/m3, cylindrical compressive strength of 19.67 MPa, 1 h water absorption of 0.31 %, and chlorine content of 0 after sintering at 1150 °C for 20 min. Chlorine in MG ceramsite enters into the tail gas or secondary fly ash in the form of chlorine salts and chlorine-containing gas when the sintering temperature is above 800 °C. The MG ceramsite prepared from MSWI fly ash meets the lightweight aggregate standard and are environmentally friendly. However, the disposal of tail gas and secondary fly ash needs attention when the MSWI fly ash is used as one of the main raw materials to prepare ceramsite.

An analytical dynamic force model for sawing force prediction considering the material removal mode

Diamond circular saw blades are indispensable tools in the industry of granite processing. Accurate prediction of sawing force is essential for optimizing the processing in advance. In this study, the calculation method for uncut chip thickness and instantaneous chip thickness was improved based on granite sawing characteristics. Furthermore, an analytical prediction force model was proposed in view of deep and intermittent grinding, which comprehensively considers the characteristics of diamond grits (including grit size, location distribution, and protrusion height) and material removal mode. The error between the predicted results and the experimental results is <12 %, indicating that the model can accurately predict the cutting force. The proposed analytical model provides a method to optimize the sawing parameters without the need for extensive experiments. This model can also extend to calculate parameters such as energy consumption and carbon emissions in the stone processing industry.

Modeling for prediction of sawing force based on the maximum undeformed chip distribution in the granite sawing

Sawing by circular saw blades is predominant in the mechanized treatment of natural stone. The predictive sawing force is crucial for optimizing, controlling, and monitoring the sawing process. In this work, a novel model for predicting sawing force, which is based on the distribution of the undeformed chip thickness at the sawing contact arc, was proposed. Based on the analysis of the undeformed chip geometry of the circular saw blade, the segment surface was divided into the front end and rear end according to the contact pattern between the segments and granite, and the models of the maximum undeformed chip thickness of diamond particles on the front end and rear end were established. Results showed that the new proposed force model fully considered the distribution of undeformed chips compared with the current model. The novel model has higher prediction accuracy, the mean maximum absolute error is within 3.77%, and the maximum absolute error is within 7.83%. Through theoretical analysis, the ratio of the maximum undeformed chip thickness of the front segment to the rear segment is 1.67, which can fully explain the wear non-uniformity of the segment. The proposed model is of great significance to the optimization of the saw blade structure and process parameters.

Analysis of diamond wear morphology and segment wear evolution during the process of hard granite sawing

Diamond circular sawblade has been widely used in hard granite processing. In this study, the wear mechanism and wear evolution of the diamond segment were investigated. The wear morphologies of diamond grits were classified as emerging diamond, whole diamond, crack diamond, blunt diamond, micro-fractured diamond, macro-fractured diamond, wear flat diamond, and pull-out diamond, which is based on sufficient observation data. The main form of diamond wear is fracture. The fracture morphology of diamond grit dominates by cleavage, which is brittle transgranular fractures, and the microscopic features are fracture steps and river-like patterns. Since the {111} crystal plane has the largest interplanar spacing among all the crystal planes, cleavage fractures tend to occur on this crystal plane. Through the scratches and pitting on the diamond grit surface, it proved that the wear process is a mixed type of two-body wear and three-body wear. However, some diamond grits exhibit special fracture morphology and are without the typical characteristics of cleavage fracture. Combined with internal factors (including microstructures and internal defect) and external factors (including chip flow, thermal load and mechanical load), the mechanism of various diamond wear morphologies and segment wear phenomena observed in the sawing experiment is clarified. Finally, the evolution process of the diamond failure and segment wear are described. The research systematically revealed the mechanism of segment wear and the fracture morphology characteristics of diamond grits in the sawing granites, which can further improve the understanding of segment wear and provide theoretical guidance for segment design.

Porosity of Calcium Silicate Hydrates Synthesized from Natural Rocks.

In this work, the suitability of natural raw materials with various modifications of SiO2—granite sawing waste (quartz) and opoka (a mixture of cristobalite, tridymite, quartz, and an amorphous part)—for the 1.13 nm tobermorite and xonotlite synthesis is examined, and their specific surface area, pore diameter and volume, and the predominant pores are determined. Hydrothermal syntheses were carried out at 200 °C for 12 and 72 h from mixtures with a molar ratio of CaO/SiO2 = 1.0. X-ray diffraction analysis, simultaneous thermal analysis, and scanning electronic microscopy were used, which showed that in the lime–calcined opoka mixture the formation of crystalline calcium silicate hydrates takes place much faster than in the lime–granite sawing waste mixture. The high reactivity of amorphous SiO2 results in the rapid formation of 1.13 nm tobermorite and xonotlite (12 h). According to Brunauer, Emmet and Taller (BET) analysis data, this product features a specific surface area of ~68 m2/g, a total pore volume of 245 × 10−3 cm3/g, and has dominating 1–2.5 nm and 5–20 nm diameter pores. This porosity of the material should provide good thermal insulation properties of the products made from it as no air convection occurs in the fine pores.

Wear characteristics of diamond segments on multi-blade combination saw with different diameters in granite sawing

In this paper, the wear characteristics of diamond segments adopted to multi-blade combination circular saw with different diameters were compared and investigated in the process of granite through an experiment. Load model with a diameter as the variable of combination saw was established based on the maximum undeformed chip thickness of a single particle. Combined with the load model, scanning electron microscope, laser microscope and vernier calipers were used to comprehensively analyze the wear characteristics of segment form the aspects of the wear morphology of diamond and metal matrix, the particle protrusion height, and the abrasion loss of segment. The results indicated that load nonuniformity of diamond generated by diameters change of saw blade was the main reason for segment wear discrepancy of large and small diameter saw blade when rocks were sawed by combination saw, and abrasion loss of segment adopted to small diameter saw blade was significantly higher than that of large-diameter saw blade. Diameter variation of saw blade in combination saw caused the different wear mechanism of diamond in segment, pulled-out and macro-fractured crystals were dominant in small-diameter saw blade, then the proportion of whole particles increased in segment used to the saw blade of large diameter. Particle protrusion height was related to the diameter in the combination saw. The high protrusion height of particles existed in the large-diameter saw blade.

Peculiarities of xonotlite synthesis from the raw materials with different SiO2 activities

In this work, the peculiarities of xonotlite hydrothermal synthesis at 200 °C from lime and SiO2 materials with different pozzolanic activities (AP) were investigated: calcinated opoka (Ap = 170.1 mgCaO kg−1), granite sawing waste (Ap = 52.2 mgCaO g−1) and reagent SiO2·nH2O (Ap = 336.8 mgCaO kg−1). By XRD, DSC, TG, SEM, FT-IR methods have been shown that the formation of crystalline calcium silicate hydrates and the sequence of the intermediate phases existence are influenced not only by SiO2 component activity, but by other factors too. The use of the most active raw meal with SiO2·nH2O results in a very rapid formation of z-phase, C–S–H(I) and gyrolite, which hardly recrystallize into thermodynamically stable mineral—xonotlite. The impurities in the starting materials may promote the formation of some other compounds and retard the synthesis of stoichiometric ones: high content of Al-containing minerals in granite sawing waste (15.41% of Al2O3) predetermines that 1.13 nm tobermorite even after 72 h of hydrothermal curing did not recrystallize into xonotlite. Regardless of its average activity, calcinated opoka is an excellent material for the synthesis of crystalline calcium silicate hydrates. Amorphous SiO2 from opoka begins to react first, followed by tridymite and cristobalite. 1.13 nm tobermorite and xonotlite are formed at the beginning of the hydrothermal synthesis (4 h), and this greatly reduces the probability of the existence of amorphous phases.

Rheological and strength properties of self-compacting concrete incorporating marble and granite powders

The use of waste products like fly ash in self-compacting concrete (SCC) is a common practice. In regions where a lot of waste generated due to sawing and polishing of granite and marble has a huge potential of using them in concrete without compromising the rheology and strength. This paper presents the experimental investigations on rheological behavior (T500, Vft, and viscosity) and strength properties (compressive, flexural, and splitting tensile strengths) of SCC made of marble and granite powders. The comparison was made with higher fly ash and higher sand content concrete mixes. The rheological properties showed similar and linear inter-relationship between different sets of mixes. Most of the mixes fall under VS2/VF1 and VS2/VF2 categories of EFNARC specifications. The strength properties of SCC mixes were compared with normal concrete mixes and found analogues with control concrete mix. The use of marble and granite powders up to 360 kg/m3 was studied. There is a beneficial effect due to the reduction of other raw materials significantly in concrete mixes. The admixture dosage was identified and found to be dependent on the surface area of particles.

Study on force distribution and its location in granite sawing

The present work proposed a model of the location of resultant force based on tangential force distribution. Afterwards, the actual location of resultant force was calculated based on the analysis of the force components in the sawing contact zone. Based on the experimental results, it is found that the distribution coefficient and the location of the resultant force are both great influenced by depth of cut and workpiece feed speed except sawblade speed. The value of the distribution coefficient ranges from 1.375 to 0.416, and the location of the resultant force ranges from 0.727 to 0.568, which both decrease with the increase of depth of cut and workpiece feed speed. Furthermore, a good corresponding relationship between the location of resultant force and the distribution coefficient was obtained, which not only validates the force location model but also further reveals the characteristics of force distribution and its location in the contact zone.

Reusing granite sawing waste in self‐compacting concrete with polypropylene fiber at low‐volume fractions

This study aims to experimentally investigate the possibilities of reusing Granite Sawing waste (GSW) in Fibre Reinforced Self Compacting Concrete (FRSCC) using Polypropylene (PP) fibers. The effectiveness of GSW at 5, 10, 15, and 20% by weight instead of cement was investigated. The PP fibers were used at volume fractions of 0.05, 0.1, and 0.15%. In order to study the microstructure and to identify the elements of the FRSCC, SEM was used. Fresh and hardened properties were evaluated. Flyash was used as an additional mineral admixture while superplasticizer was also added to achieve required flow parameters. The GSW along with PP fibers increases the compressive strength of FRSCC. An improvement in splitting tensile strength was also observed.

Applications of green materials for the preparation of eco-friendly bricks and pavers

The most basic and primary building material for construction of houses is the conventional brick. The rapid growth in today’s construction industry has obliged the civil engineers in searching for more efficient and durable alternatives far beyond the limitations of the conventional brick production [1-2]. A number of studies have been made and serious steps have been taken in manufacturing of bricks from several waste materials. However, the traditional mean of bricks production which has brought hazardous impacts to the context has not yet been changed or replaced by more efficient and sustainable one [3], [4]. Most of the researches went through enhancing the clay brick quality and properties by mixing the clay with various recycled wastes as foundry sand, granite sawing waste, harbour sediments, perlite, sugarcane, baggase ash, clay waste and fine waste of boron, sewage sludge, waste glass from structural wall and other different wastes. Compile this state of the art work of manufacturing bricks in the past and the current trend in the bricks industry with respect to the raw materials, ways of manufacturing and the out- comings.This project presents an experimental study on the utilization of waste materials which replaces clay with (Plastic covers, Ceramic Powder, Egg Shell Powder, GGBS, Silica Fume, Rice Husk Ash and Lime Powder) and Fine Aggregate with (Recycled glass, Dry Grass, Dead Leaves, Tree barks powder, Sugar cane powder, crumbed rubber) to produce eco-friendly Bricks. This project is an attempt to fill the gap of the past studies and suggest more sustainable and sophisticated methods of brick manufacturing in the future. 40 percent replacement of fine aggregate with crumbled rubber and dry grass in mortar bricks have given encouraging results, also the replacement of cement by egg shell powder at 20% has given a considerable result

Development of a method based on MADM theory for selecting a suitable cutting fluid for granite sawing process

Abstract The stone processing sector has begun to implement the Cleaner Production (CP) strategy to tackle with these burdens caused by the production process. Decision-makers need to select the most suitable cutting fluid for achieving the CP mode in their firm. However, the assessment methods of characteristics and performances of cutting fluid in granite processing field have rarely been examined in the literature. This paper proposed a multi-criteria evaluation system that enables decision-makers to quantitatively analyze the comprehensive effectiveness of application of cutting fluid in their granite production lines. A four-hierarchy indicator system was initially structured with three attributes, 13 characteristics and 30 indicators according to the context and literature of the stone processing field. The definitions of measurement method for all the indicators were closely related to the laws, rules, regulations and discharge standards. The decision algorithm was designed based on the integration of two distinctive Multiple Attribute Decision Making (MADM) techniques: Analytic Hierarchy Process (AHP) approach was used to determine the weights of each indicator, and the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) technique was applied to obtain the prioritization of alternative cutting fluids. This research introduced the statistical analysis principle to help the decision makers to further understand the nature of the final ranking: confidence interval (CI) provided the decision-makers an interval where the ranking may be valid instead of a single absolute rank; and Tukey's HSD tests were done to show if the final score of alternatives were statistically different from each other. A case of application demonstrated that the proposed decision method and procedures can become a scientific foundation for formulating guidelines to select the most suitable cutting fluid for implementing CP strategy in the granite processing organizations.

Durability studies on fibre reinforced self compacting concrete with sustainable wastes

The sustainable development in construction can be achieved by using industrial waste products in concrete. This work aims at developing a new composite by incorporating Granite Sawing Waste (GSW) in Poly Propylene fibre (PP) reinforced self compacting concrete along with Fly Ash(FA). Shrinkage studies and durability studies like water absorption, porosity, acid resistance, sulphate resistance and chloride penetration have been done. It is found that the shrinkage of Self Compacting Concrete (SCC) is considerably reduced by using GSW and PP fibre. Resistance against acid attack and chloride penetration are found to improve. Reduction in water absorption and porosity are found to be better than control concrete up to 10% of GSW and the sulphate resistance is improved.

Preparation and Properties of CaO-MgO-Al&lt;sub&gt;2&lt;/sub&gt;O&lt;sub&gt;3&lt;/sub&gt;-SiO&lt;sub&gt;2&lt;/sub&gt; Glass-Ceramics from Granite Wastes

Granite process industry generates a large amount of wastes, which pollute and damage the environment. This work aims to investigate the possibilities of using the granite sawing wastes in the production of glass-ceramics. Granite wastes with other components were used to prepare glass-ceramics. The crystallization behavior and properties of the glass-ceramics were investigated. The results showed that the activation energy for crystallization (Ec) was 463 kJ/mol and Avrami parameter (n) was 2.68, suggested a two dimension crystal growth mechanism. The main crystalline phase of all the obtained glass-ceramics was diopside. With the increase of heat treatment temperature, the diffraction peak intensity of diopside firstly increased and then decreased slightly. The minor crystalline phases spinel and Mg4Al2Ti9O25 were observed above 970°C. When heated at 970 °C for 1h, the sample exhibited the highest Vicker's hardness and bending strength values, 7.3 GPa and 151 MPa, respectively. And the glass-ceramics showed better acid resistant than alkali resistant.

A probabilistic fatigue failure analysis for FRSCC with Granite sawing waste

A probabilistic fatigue failure analysis for FRSCC with Granite sawing waste

Wear of Monolayer Brazed Diamond Beads in Wire Sawing of Granite

The wear behavior of monolayer brazed diamond beads was investigated during wire sawing of granite. Diamonds were bounded onto the beads by brazing in vacuum. Brazed beads were abrasive sawed on a wire sawing machine and the wear of the brazed diamond beads were traced and observed by using a digital microscope. The results reveal that the wear of root fractured, characterized by breaking off grit at its bonding level, was the fatal failure of the cutting ability of grit as well as the main wear behavior of brazed grits on brazed bead.

Granite waste and coffee husk ash synergistic effect on clay-based ceramics

Brazil produces massive amounts of granite sawing waste and coffee husk ash and their inadequate and, often, illegal disposal causes enormous environmental problems. In the past decade, these and other industrial wastes have been intensively studied aiming at determining their potential as alternative raw materials, particularly for the ceramic industry. This work describes research carried out on the joint incorporation of those wastes in ceramic roof tile formulations. The results indicated that the simultaneous use of both materials translates into a very forgivable industrial working range, both composition- and temperature-wise, which, given the technological properties values observed after firing at 1100°C, enables industrial up-grade to wall tile production. As collateral benefits, the use of granite waste and coffee husk ash as alternative raw materials in the manufacture of clay-based products will relieve the stress on feldspars consumption and attenuate waste disposal concerns.

Use of the Processed Waste from Kaolin and Granite Sawing in the Manufacture of Tubular Ceramic Membranes

The incorporation of waste from various industrial activities in ceramic products comes as a technological alternative to reduce the environmental impacts caused by the indiscriminate disposal of wastes in the environment. The kaolin and granite processing industries have been mentioned as sources of contamination and pollution, due to the enormous amounts of wastes they produce. The use of these wastes as raw material and its transformation into products that can be commercialized and/or show economic viability, presents as an alternative to the industries. The aim of this work was to use ceramic masses incorporated with kaolin waste (35%), granite (35%) and bentonite (30%) for the confection of tubular ceramic membranes using extrusion as production process. The ceramic mass was characterized through analysis techniques of thermogravimetric, chemical, particle size and X-ray. The membranes produced, after sintering in temperatures of 850, 900, 950 and 1000oC, were submitted to characterizations of scanning electron microscopy, mercury porosimetry and permeability test by tangential flow. The preliminary result of the particle size analyses identified that the ceramic mass presents an average particle diameter of 37.00μm. The membranes presented porosity of approximately 32%, and average pore diameter within the ultrafiltration range.

Utilization of granite sawing byproducts in self consolidating concrete

Utilization of granite sawing byproducts in self consolidating concrete