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.

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?

    Diamond wire saw is a wire saw made from diamonds. It is used for cutting and grinding hard materials, such as concrete, stone, and metal. Diamond wire saws are also used in jewelry making and other applications where a very strong and durable wire saw is needed.

    Diamond wire saw is made by bonding diamonds to a metal wire. The diamonds are usually attached to the wire saw using an industrial adhesive. The bond between the diamonds and the wire saw must be strong enough to withstand the forces exerted on the wire saw during use.

Working of Diamond Wire Saw

   The principle of a diamond wire saw is comparable to that of a reciprocating saw or bandsaw, as it uses the same mechanism. The Diamond wire is used to cut materials that must be sliced or threaded through a borehole and then rushed at high speed to exploit abrasion to chop through the slab or reinforced steel efficiently.

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   The first option is to cut the wire using a fast-cooling method, which generates heat and requires cooling. The primary way to cool something is with water, oil, or specialized cutting fluid that is constantly supplied to lubricate the wire.

What are the Benefits of Using a Diamond Wire Saw?

    The primary benefit of using a diamond wire saw is that it can cut or grind through extremely hard materials that would otherwise be impossible to cut or grind with traditional methods. Diamond wire saws are also much more precise than other cutting or grinding tools, making them ideal for applications where accuracy is critical.

    Diamond wire sawing is popular because it cuts through most materials more quickly and efficiently than old cutting methods. It produces significantly less trash when compared to conventional teeth-like blades, which can save money in the long run.

    Wire sawing is clean, fumeless, and quiet, with little to no vibrations, making it safe for sensitive work settings such as a hospital or school. The new machine is four to five times faster than traditional cutting processes, and it requires minimal human resources to run.

Diamond Wire Sawing Application

   Diamond wire sawing can be utilized to cut through a wide range of materials, including those that are softer than diamond. Almost any substance may be used, including stone, masonry, cast concrete, and steel. Diamond wire sawing's incredible strength makes it a popular solution for controlled demolition projects such as safely and efficiently removing concrete structures.

Diamond Wire Sawing Underwater

    Cutting can be necessary for situations where the ground is immersed underwater. Diamond wire sawing is a fantastic method to cut underwater, as it does above ground. Wire sawing is a particularly beneficial tool for firms such as water companies, who may need to cut through concrete or steel pipes for routine maintenance work.

Application of Diamond Wire Sawing

Diamond wire sawing is a powerful cutting technique that is perfect for removing huge, heavily reinforced thick sections of concrete and other purposes.:

• Demolition tasks
• Large steel structures, such as decommissioning mine sites, can be dismantled.
• Best for cutting through thick/ reinforced concrete structures, such as bridges, dams, factory floors, jetties, columns, or beams.
• To cut a structure from floor to ceiling.
• Cutting in restricted, limited, and sensitive regions
• Cut through sturdy steel and embedded iron using this machine.
• Can be used in cutting Concrete, Marble, Granite, Limestones and other stones, Fragile Crystals, Substrates, Stones, Foams, Metal Parts, etc.

What are the Disadvantages of Using a Diamond Wire Saw?

    The main disadvantage of using a diamond wire saw is the cost. Diamonds are very expensive so diamond wire sawing can be quite costly. Additionally, diamond wire saw requires special care and maintenance to ensure that they last long.

Pre-Cautionary Measures

    During a wire sawing operation, the operator keeps an eye out for any wires that may be cut due to over-tensioning and makes sure they are sliced in a skilled manner. If necessary, the pulley arrangement should be readjusted by the operator.

    The diamond wire sawing is a powerful cutting technique that can cut or grind through most materials more quickly and efficiently than other methods. The primary benefit of using a diamond wire saw is its precision, making it ideal for applications where accuracy is critical. Diamond wire saws are also much less noisy and vibrate less when compared to conventional teeth-like blades, making them safe for sensitive work settings such as hospitals or schools. However, the main disadvantage of this method is costly diamonds and diamond wire saw must be replaced often due to wear and tear from usage (especially if they’re working with concrete). To avoid costly replacements, experts recommend taking preventive measures during operation by monitoring tension on diamonds to make sure they are not cut and adjusting the diamond wire saw’s path frequently to distribute wear and tear evenly.

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