WANLONG
During the use of wire saws, unexpected malfunctions may occur. Without a detailed understanding of the issues, one might feel unsure about how to address them. Below are two common malfunction scenarios and their solutions.
Carcass and matrix layering
This refers to the phenomenon where the bonding material detaches partially or entirely from the core during the use of the wire saws.
Cause Analysis:
1. The sintering process used by the manufacturer is unstable, and before leaving the factory, the bonding material and the core did not reach a sufficiently strong adhesive strength.
2. During use, excessive cutting pressure or other external forces cause the bonding material and core to separate.
Solutions:
1. Manufacturers should stabilize the production process and provide qualified products.
2. Reduce the cutting depth and use the saw according to proper guidelines.
Polishing
At the beginning of using the wire saws, improper operational techniques may lead to the diamond segments on the beads’ surface being polished, increasing cutting resistance to the point where the saw can no longer make normal cuts, losing its cutting ability. A common indicator of this is when the cooling water turns from turbid to clear during the process, especially when cutting large, less abrasive stones like granite in mining operations.
Cause Analysis and Solutions:
1. Excessive Line Speed at the Start of Cutting:
– Generally, when starting a cut, the rotational speed should be reduced to 80% of the normal cutting speed before the wire saws fully penetrates the stone. For example, if the normal cutting speed is 25m/s, the initial cutting speed should be reduced to 20m/s to avoid the polishing effect.
2. After Penetrating the Stone:
– Once the wire saw has entered the stone, the line speed should be adjusted to the normal cutting speed. After setting the speed to normal, the working current of the machine should be increased to the rated current to improve cutting efficiency. If the machine power is not increased after adjusting the speed, the cutting speed will slow down over time, eventually leading to polishing.
3. Excessive Cooling Water:
– The amount of cooling water should be adjusted to a moderate level as specified in section 6.2.4.
