Solution of Stone Slabs Bending Caused by Circular Cutting Saw Blades
In the following, we will talk about the Solution of Stone Slabs Bending. During the production process, stone processing plants should fully consider the accuracy of the selected cutting machine, the quality of the diamond segments, the accuracy of the core and the degree of re-welding, and comprehensively consider the difficulty of cutting the stone, and formulate develop a reasonable sawing process and strictly implement it.
Most of the granite stone is cut with a diamond circular cutting machine. It has a simple structure and strong sawing maneuverability. According to the process, the block can be cut at will. However, in the process of use, the bending of sawed slabs has always been the most headache and the most difficult problem for enterprises.
Problems of circular cutting blades
The first manifestation of stone sawing bending is the extremely poor flatness of the slab in the length direction of the sawing. It is called left and right bending. The second form of stone sawing and bending is the extremely poor flatness in the direction of sawing depth, which is called up and down bending. At present, the experience of some stone factories is worth learning from. When the slab is bent, appropriately reduce the amount of cutting and increase the speed of horizontal cutting. When the left and right bending occurs, appropriately increase the amount of cutting and reduce the horizontal cutting speed, the effect is obvious. Therefore, in the daily production management, we must strictly implement the mature cutting process. When the phenomenon of bent slabs occurs, an in-depth and detailed investigation and analysis of the cutting process and implementation should be carried out first. Suggestions for rectification and preventive measures can be put forward, which can get more results with less effort.
Solution of Stone Slabs Bending
It is generally believed that the main reasons for the stone cutting damage are that the quality of the saw blades (finished product) and the blade sawing machine used. And the formulation and execution of the sawing process in the customer’s processing are directly related. In addition, it is related to the overall quality of the sawing machine. The installation and maintenance of the sawing machine, and the cooling and lubrication of the cutting process.
1. Saw blade core, the most important solution of stone slabs bending
Generally, the new saw blade core is controlled for tension value and flatness and end face runout before leaving the factory. However, when some cores are used in stone factories, deviations often occur, resulting in a decrease in the qualified rate of slab cutting. The main manifestations are: the processing technology used in the stone processing plant does not match the core tension value. When the positive tension value is too large, it will easily cause up and down bending. Some cores have reached the service life limit after repeated re-welding, will also end up in this kind of phenomenon. Therefore, the stone processing factory should not be greedy for cheap price when selecting the core, and choose the substandard core. But should choose the core with good quality produced by qualify enterprises. At the same time, pay attention to the use cycle of the re-welding blade to reduce unnecessary losses.
2. Diamond Segments
The cutting and bending of the slabs is mainly because the diamond segments are not sharp. The balde is forced or overloaded under overload, resulting in excessive cutting current and bending of the slabs. Therefore, before cutting, the stone processing plant should take chisel ground for the new diamond segments. If necessary, mechanical chisel ground can be used to reduce the difference between the runout and end jump. However, some stone processing plants have poor conditions and cannot use mechanical chisel ground. But use random chisel ground. In the process of chisel ground, the strict cutting and cutting process should be formulated and executed according to 1/3 or 1/4 of the normal cutting or walking speed. And the “blade” should be fully “sharpened” to reduce the radial runout of the blade error. Otherwise, in the process of cutting or cutting under overload, the saw blade core cannot bear a huge load. It will cause the flatness, tension value, and end-face runout to deteriorate.
3. Welding of core and diamond segments
Qualify diamond segments welding (re-soldering) manufacturers generally use high-precision automatic welding machines with high-precision molds, strict and detailed welding processes and quality inspection standards. It can effectively control the influence of the blade heating during welding on the flatness of the base of the saw blade, the amount of end face runout, the amount of radial runout and the tension value, effectively avoiding reducing the chance of the slab bending during the cutting process.
At the same time, the mixing ratio of the diamond segments to the core (the ratio of the thickness of the diamond segments to the thickness of the core) is also an important factor that cannot be ignored. If it is too small, the bending of the slabs will occur when the cutting depth exceeds 1/2 of the radius (generally the manufacturer believes that the cutting effect is better when this value is 1.25 ~ 1.35). Therefore, when the stone processing enterprise performs the blade welding (re-soldering), it is necessary to choose a qualify blade welding factory with better conditions to ensure the high quality of the saw blade finished product and efficient cutting, reducing losses and waste.
4. The running quality of the saw machine
According to a survey, the saw’s horizontal running guide rails wear down after a period of use, the accuracy is reduced. And the required quality control is not achieved standard, when crawling occurs, the slab is prone to bending left and right. When the longitudinal (vertical) lifting civil rail part of the saw is worn. The accuracy is lowered and the slab is prone to buckling when the accuracy is not reached. At the same time, when the gap between the inserts of the guide rail of the saw is not adjusted properly or when foreign objects enter the guide rail. It is easy to produce a bending phenomenon. In addition, the poor operation system of the main shaft of the saw is also an important factor that causes the bending of the slabs. Therefore, the accuracy of the main drive shaft of the saw and the reasonable adjustment of the bearing clearance of the main shaft are also very important. Otherwise, irregular slab bending will occur.
5. Installation and maintenance during the use of the saw
In addition to the normal maintenance and timely removal of guide rail foreign objects during the use of the saw. The precision requirements for the saw blade flange are particularly strict when replacing the saw blade. Before replacement, it is necessary to strictly check the flatness of the flange, the amount of runout on the end face, and clear the burrs and foreign objects. If the difference does not meet the quality control requirements, it must be repaired or replaced.
At the same time, the minecart runs smoothly, and it is very important to keep the cart securely on the car and check it frequently during the production process. It is also critical to ensure the straightness of the trolley’s running rails and no foreign objects.
6. Cooling and lubrication during sawing machine cutting
In order to ensure the normal cutting of the saw blade and extend its service life and improve the quality of the cutting slab during the use of the sawing machine. A special stone cutting coolant is usually prepared. And maintain the stable quality of cooling and lubrication during the production process, and the flow is sufficient and evenly sprayed on the saw blade core. Some users do not use prepared coolant, but use tap water for cutting and cooling, which significantly reduces the re-welding times and service life of the core and affect the quality of slabs. Therefore, good cooling and lubrication can fully and effectively increase the service life of the saw blade, reduce cutting costs, and prevent the occurrence of slab bending.