Emre Yilmazkaya, Yilmaz Ozcelik

Development of Cuttability Chart for a Marble Cutting with Monowire Cutting Machine

Introduction

Development of cuttability chart for a marble cutting with monowire cutting machine. Develop a cuttability chart for marble cutting using a monowire machine. Optimize cutting parameters to reduce diamond wire wear and energy, improving efficiency.

Abstract

Monowire block cutting machines can be used for natural stone block squaring operations and slabcutting operations from natural stone blocks. The efficient use of these machines reducesoperating costs by ensuring less diamond wire wear and longer wire life at high speeds. Thepurpose of this study is to develop cuttability chart for real marble sample based on unit wear andunit energy in monowire cutting system and also perform cutting optimization. For this purpose, thefull automatically servo controlled monowire cutting system which can cut blocks in threedimensions were developed in Hacettepe University Mining Engineering Department. Cuttingexperiments were performed at different wire rotation speed (peripheral speed) and wire downwardmovement speed (cutting speed) on the real marble block which was transported to the laboratory.A cuttability abacus in monowire cutting system taking into consideration the unit energyconsumption during cutting operation and unit wear on diamond beads was developed with DesignExpert 7.1 software for real marble sample by using the results obtained.

Review

This study presents a practical and relevant investigation into the optimization of monowire block cutting operations, a critical aspect for the natural stone industry. The core objective, to develop a "cuttability chart" for marble based on unit wear and unit energy, directly addresses the industry's need for reduced operating costs and enhanced efficiency. The approach of considering both diamond wire wear and energy consumption simultaneously provides a holistic perspective on cutting performance, moving beyond single-factor optimization. The use of a custom-developed, fully automatic, servo-controlled monowire cutting system at Hacettepe University's Mining Engineering Department suggests a robust and well-controlled experimental setup, adding credibility to the derived results. A significant strength of this work lies in its empirical foundation, conducting experiments on real marble blocks and meticulously varying key parameters such as wire rotation and downward movement speeds. This direct experimentation, rather than simulation, ensures the applicability of the findings to industrial scenarios. The development of a "cuttability abacus" using DesignExpert 7.1 software based on these experimental results is a commendable analytical approach, indicating a systematic effort to model the complex interplay of cutting parameters, wear, and energy. Such a chart would be invaluable for machine operators and manufacturers in predicting performance, optimizing settings, and ultimately extending tool life while maintaining high productivity. While the abstract clearly outlines the methodology and aims, the full paper would likely elaborate on the specific ranges of speeds tested and the detailed characteristics of the "real marble sample" beyond just its material type, which could further contextualize the findings. Nevertheless, the abstract strongly suggests that the research provides a valuable tool for operational efficiency and cost reduction in natural stone processing. The practical implications of a well-developed cuttability chart are substantial, offering a data-driven approach to optimize machine parameters and contribute to more sustainable and economical natural stone production. This work appears to be a solid contribution to the field of natural stone processing technology.

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