What is the Advantage and Disadvantage of concrete diamond wire saw ropes

The old blasting quarry method causes serious environmental damage and wastes resources. Now, the most popular mining method is diamond saw rope cutting.

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Advantages of using diamond saw rope for stone Compared with the traditional “blasting + flame cutting” quarry method, the advantages of using diamond rope for quarry are:

Wide adaptability:

Diamond saw rope can be used for all types of mines, while flame cutting is only suitable for granite mines with high quartz content and few cracks.

Strong functionality and high efficiency:

First, the quarry depth is deep, which can reach 10-20m or even deeper, while flame cutting is generally only within 10m; secondly, the cutting speed is fast, generally reaching 3~4m2/h, which is 2~3 times that of flame cutting.

Multifunctional:

The saw rope can cut in vertical, horizontal, inclined, and other directions, and can also perform blind cutting, while flame cutting can only cut vertical surfaces.
First, the cut surface of the saw rope is very flat and will not cause any internal damage to the rough material. Secondly, the cutting gap is small, only about 11mm, which will not cause a waste of resources; while the flame cutting surface is rough and uneven, and will damage the materials in other areas, and the cutting gap is large, generally 100~300 mm, causing great waste of resources, and the quarry cost is also high.

Safety and environmental protection

Diamond saw rope quarry is noiseless and dustless, does not affect nearby residents and other construction, and has a high degree of automation, separate control, low labor intensity of workers, and high safety; while flame cutting noise and dust are very large, seriously affecting the operation of nearby residents and other workers, and the labor intensity of workers is very high, and the safety performance is also low. Therefore, the use of diamond saw rope to mine ore has significant economic and social benefits.

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Multiple factors associated with diamond saw rope include the sawing life of the rope beads, the sawing speed of the beads, the spacing of the beads in the warehouse, mold design, and the rope’s life under normal working conditions.

Common problems of diamond wire rope

Diamond saw rope breakage

Usually, the wrong application parameters are used or the quality of the saw rope is too poor, which means that the plastic or rubber is not firmly bonded to the diamond beads, causing rock chips to enter the diamond saw rope, and soon the steel rope will be partially contacted and rubbed between the beaded steel body and the steel rope, and the steel rope link thread will begin to break. This may also be due to the wrong use of the binder. The breakage of the steel rope may also be caused by the wrong selection of wire rope, beaded steel body, and poor heat treatment after injection molding.

Peeling of diamond saw rope beads

If the beaded cutting layer partially peels off from the beaded steel body, it is usually due to the improper selection of the matrix or incorrect sintering parameters. Usually, the incorrect cold pressing process is also the cause of peeling. Sometimes it may also be due to improper rain dewaxing process, causing paraffin to penetrate between the metal matrix and the beaded steel body. It is also related to improper cleaning of the beaded steel body.

The beads are not firmly bonded and the beads are loose. Usually, this is a signal of a problem with the injection molding. It may also be due to improper selection of wire rope, internal contamination of the diamond threading, and improper cleaning, which leads to a loose bond between the beads and the injection molding.

What is diamond wire saw rope?

Diamond rope is a component of diamond wire saw (also known as diamond rope) and the main cutting part for cutting stone and concrete. In terms of design, 33, 37, 38 or 40 ropes are connected in series with wire rope, and then The wire rope surface is wrapped with plastic, spring or rubber to form a wire saw. Diamond rope contains diamonds. When cutting stone or concrete, hydraulic pressure and the rapid rotation of the flywheel are used to drive the diamond to grind these hard materials. Through continuous grinding, the cutting process is finally completed.



Diamond wire saw rope types

The types of diamond rope can be divided according to the production process: sintered rope (produced by hot-press sintering process), electroplated rope (the earliest rope process, electroplating by electroplating solution), vacuum brazing rope (through vacuum brazing in production).

Diamond rope can be divided according to the diameter: the diameter of the rope can be made into any specifications from 5.3-12.5mm,the common specifications are 5.3, 6.4, 7.2, 8.0, 8.5, 8.8, 9.0, 9.5, 10, 10.5, 11, 11.5, 12 , 12.5mm and other specifications,but the thinest wire saw can be 2.4mm.
Diamond rope can also be distinguished by shape: single-layer rope (mainly the matrix of a layer of cutter head, but also a more common rope shape, especially the rope of sintering process, almost all of this kind), double-layer rope (main structure For the double-layer structure, brazing ropes currently use this shape more often).

Divided according to the cutting object: At present, there are three main categories of rope. The first type is used for steel-concrete cutting. This type of material needs to cut steel bars and hard-structured concrete. The cutting materials are more complicated and require very high sharpness. The use of high sharpness, high abrasiveness, and the need for more stable diamond. The second type is the rope used for granite cutting. This rope needs to cut stone with extremely high hardness, and the stone cannot be chipped due to the material required, which is higher for continuity and efficiency. The third type is cutting marble, which is softer, so the brazing wire saw can be widely used for this at present.



What are the advantages of diamond rope compared to cutter head cutting?

Compared with the cutter head, the diamond rope has a smaller volume, and due to the particularity of the wire saw, it can cut a larger area, and the processing machine is also extremely convenient to handle, and it is less restricted by the site environment, but the disadvantages are also very obvious. For example, it cannot be reused, and the price is more expensive.

Diamond wire saw, wire saw rope

At present, Linxing Diamond Tools Co., Ltd. mainly produces sintered wire saw ropes with diameters of 10.5mm, 11mm, 11.5mm, 12mm and 12.5mm, which are mainly used for marble mining wire saws, granite mining wire saws, and quartz wire saw for quarry mining, wire saw for volcanic rock mining, steel-concrete cutting, etc. Other sizes of rope can also be customized. 

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