The Effect of Geological Properties of Dimension Stones on the Prediction of Specific Energy (Se) During Diamond Wire Cutting Operations

Abstract

Given the increasing demand for dimension stones, mining operations in quarries have always been an important branch of mining engineering. Among different techniques, diamond wire cutting is one of the most common methods of dimension stone mining. A reliable assessment and accurate prediction of diamond wire cutting performance are essential for feasibility analysis and operational planning in this area. This performance depends on factors such as physical, mechanical, and textural properties of the rock and the characteristics of cutting operations which can be evaluated by criteria such as specific energy, production rate, efficiency, and diamond bead wear rate. This study aims to develop a method for predicting the specific energy of diamond wire cutting in dimension stones based on rock properties. For this purpose, the specific energy of diamond wire cutting in 11 different igneous rock samples was measured. Given the high strength and abrasivity of igneous rocks, cutting operations in these rocks generally requires a great amount of energy. In a series of tests performed on the samples, rock properties such as uniaxial compressive strength (UCS), Brazilian tensile strength (BTS), Young's modulus, density, textural properties, abrasivity and operating factors such as pullback amperage were measured. The measured parameters were divided into four groups of physical, mechanical, textural, and operating parameters. After determining the specific cutting energy of each sample, the relationship of the energy with each individual property was investigated. This investigation showed that density, abrasivity, and p-wave velocity respectively had the highest correlation with specific energy. Using the correlation results, four input parameters (one from each of the four considered parameter groups) were selected for inclusion in the prediction model. These parameters were density, abrasivity, wave velocity, and amperage. Multivariate linear regression was then used to analyse the effect of rock properties and operating parameters on specific energy. The developed regression model showed that once the rock properties are known, the specific energy can be predicted with an accuracy of 85.8%. The proposed model can be used to estimate the specific energy of diamond wire cutting operations in dimension stone quarries in advance, and predict the amount of energy consumption, the required energy source, and the optimal cutting machine accordingly.

Geological Investigations and Production Planning by Identification of the Discontinuities and Rock Mass Blocks in Dimension Stone Quarries: A Case Study

“…The conventional method of quarrying in these quarries is the diamond wire-cutting method, which has been used since 1985 and is still used in 90% of dimension stone quarries today (Özçelik et al, 2002;Servet et al, 2014). The advantages of this method include high cutting speed, more production efficiency, and increased block production (Khoshouei et al, 2020). Figure 7 shows a quarry bench being quarried by diamond wire-cutting machines.…”

Energy consumption and wear rate of diamond beads during operation of a diamond wire saw

“…Khoshouei et al 2020 measured sawing energy on a laboratory diamond wire saw. Tests were carried out on samples of diorite, syenite, gabbro, granite and andesite (Figure 3), [13]. The results showed that the density, abrasiveness and p-wave velocity have the highest correlation with specific energy.…”

Investigating the Anisotropy Strength Index (Asi) for Some Egyptian Ornamental Stones

“…In the subject of rock mechanics and other technical properties, the concept of anisotropy is well-known. A theoretical investigation of the elastic anisotropy of a rock mass with regular joints was the first step in understand- ing how joints affect this property (Morland 1976;Khoshouei et al, 2020). The significance of rock mass anisotropy is emphasized and the connection between rock anisotropy and stress, deformability, and strength of a rock mass having a regular single joint set is discussed .…”