Date: 2025-10-24 12:57:04 149
DIAMOND WIRE CUTTING PROCEDURES FOR GRANITE QUARRY
IMPORTANT CHECK LIST WHEN SETTING UP THE SAW AND WIRE CUT
1. The wire machine’s rails should stand level approximately a minimum of 2 meters from the bench you want to cut, if you have sufficient space you calculate the height of the bench divided by two. This should be the total distance between the rails and the bench. Example: if the bench is 8 meters high, divided by two will give you 4 meters. The rails should be 4 meters from the bench that you want to cut if space is available. This allows the wire to twist sufficiently while cutting outside the cut running on the main flywheel because of the massive height or size of the bench, also eliminating ware-flat on the beads.
2. Once the wire is through the leading holes the wire needs to be twisted/turned before joining the wire with a steel ferrule. The turns on the wire should be approximately 1.5 turns per meter, steel joining ferrules should be changed every 8 to 12 hours of cutting. Once you have cut out the old ferrules alternate the turns in the wire 1.6 turns per meter up to 2.0 turns per meter. Never exceed 2.0 turns per meter because this increases the load on the inner cable which could cause damage or breakages.
3. Once the wire is ready to be started on the wire saw the operators should pull the wire a couple of times by hand until the wire move freely without effort so that the wire can initially penetrate the corners removing the sharp edges. This will assist when starting the saw that the wire does not get hooked or jammed on the sharp edges which will damage the rubber assembly. Also remember to always start up by using guide pulleys on top of the bench in front. If you standing at the saw machine and you look to the top of the bench you will see the guide pulley on the guide pulley stand.
4. The wire has been pre-sharpened already in the direction indicated on the rubber with an arrow on certain places. Please make sure the wire’s direction for cutting is correctly put into the leading hole.
5. Before starting the flywheel for the first time make sure there is not too much tension on the wire, you first want to cut and penetrate the corners before slowly increasing the tension.
6. Start up cut with vertical cutting setup a bench pulley on the edge of the bench to guide the diamond wire from the top to the main drive wheel on the saw machine while the diamond wire is still new. Even though the wire has been pre-sharpened the wire still needs to complete a few cuts before the beads are at its sharpest. If you prefer cutting without a bench pulley you may then remove the bench pulley once the beads are sharpened after the fourth cut at your own digression.
7. While cutting check that the water feeding is set correctly, there should be a thick sludge dripping of the main drive wheel.
8. On horizontal cutting also with new wire try to install at least one pulley on the wire’s penetration side until the beads are also sharp enough to increase the wire’s speed to its cutting potential. Also monitor the beads for the first two to three cuts, once its sharp at the operator’s own experience he/she may increase the wire speed and amps.
9. For the first cut with brand new wire please set the saw parameters (55/75kws wire saw) properly as below:
l 26m/s main drive wheel speed is recommended for the first cut of very hard and abrasive granite, with loading current of 80-85amps, to sharpen the new diamond beads properly. Maintain the settings to complete the first cut. Then gradually increase the main drive wheel speed up to around 28-30m/s to complete another 1-2 bench cuts.
28m/s main drive wheel speed is recommended for the first cut of soft to medium hard granite, with loading current of 80-85amps, to sharpen the new diamond beads properly. Maintain the settings to complete the first cut. Then gradually increase the main drive wheel speed up to around 30-32m/s to complete another 1-2 bench cuts.
The operator should do some spot checks by stopping the saw, checking that the beads are not bulleting (getting warned down from the front part of the bead). If bulleting or blunt of the beads are noted then start to increase the main drive wheel speed gradually with minimal water feed and still monitoring the beads which should remain cylindrical.
The diamond wire usually will get 100% sharp after the 3rd cut then the operator may start cutting at the potential speed of the wire also it will be at the digression of the saw operator. The saw’s main drive wheel may be increased to 32-34m/s or even up to 38m/s depends on loading of saw, and increase the loading current up to 90-95amps for 55kws saw, you may even increase the loading current up to 95-105amps for the 75kws saw.
10. Also note to replace the ferrule after every 8 to 12 hours and making sure that the shoulders of the beads is cleaned properly with the rubber to make a solid ferrule connection when crimping.
11. By changing the ferrules after 8 to 12 hours it will allow for the operator to alternate the wire twists between 1.5 and 2.0 twists per meter to eliminate wear flat and keeping the beads nice and cylindrical. (increase a few twists every time you replace the ferrules, but never over than 2turns per meter)
12. Once the wire has completed the first three to four cuts and the operator is satisfied that the diamonds on the beads are sharp they should try to keep the cutting speed between 10 to 12 square meters per hour and amps around 85-95 to achieve the best potential wire lifespan.
13. With the same above diamond wire and saw operation settings, the wire can usually achieve to consistent performance and a good balance of wire life as below, to meet the customers’ requirements at the best cost per square meter.
Soft granite Class 1-2 (abrasive&non abrasive)- quarry cutting: achieves to 8-15 square meter per hour in speed and 26-34 square meter per linear meter of wire life on 55/75kws variable speed quarry wire saw machines.
Medium hard granite Class 3-4 (abrasive)- quarry cutting: achieves to 8-10 square meter per hour in speed and 22-25 square meter per linear meter of wire life on 55- 75kws variable speed quarry wire saw machines.
Hard granite/quartzite Class-5 (very abrasive)- quarry cutting: achieves to 6-8 square meter per hour and 12-16 square meter per linear meter of wire life on 55-75kws variable quarry wire saws.
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