I. Introduction
As everyone knows, I have a world of stone resources. In recent years, with the rapid development of the construction industry and the improvement of people's living standards, stone has become more and more popular with its unique natural attributes, and the demand for the market is increasing. In the same way, China's stone processing technology is close to the world's advanced level, but the mining technology of stone is still far behind developed countries.
At present, there are several main ways of mining in China: blasting operation, flame cutting method, expansion agent method, etc. The mining method generally has the disadvantages of low labor productivity, low yield, low waste of resources and poor safety. In recent years, some companies have used diamond bead wire saws and diamond chain saws for mining. Although they have achieved good results, they have large equipment investment and high mining costs. How to improve the quality and efficiency of stone mining, minimize damage to the environment, reduce the labor intensity of workers, etc., has become an urgent need to solve problems in the exploitation of stone blocks in China.
Second, the principle of cutting
In view of the above situation, Chinese scientific and technological personnel have skillfully applied the plate cutting mechanism to mining, and achieved good results. The basic principle is as follows: the track is laid on the mine table, and the super large diamond circular saw blade (Ф2000~3500mm) is driven by the host to rotate at high speed to realize on-orbit cutting. Due to the advantages of low investment, high efficiency, safety, environmental protection, energy saving and low mining cost, it is widely favored by mining enterprises.
Third, technical requirements
In addition to the good precision required for the sawing machine, the specification and quality of the ultra-large diamond circular saw blade are the key to this technology. As we all know, the size of the mining blocks is determined by the size of the saw blade. At present, the market requires the width of the sheet to reach about 1.5m. Therefore, the specifications of the diamond circular saw blades that match it must reach Ф3500 or more. At the same time, the field work environment such as the flatness of the mining operation, the cooling chip removal and the like are cut relative to the plate, and the conditions are even worse. Therefore, more stringent requirements are imposed on the manufacture of the saw blade substrate.
Yichang Black Cyclone Saw Industry Co., Ltd. has developed 矿山2300mm or more mining saw blade bases in 2003 according to market demand. After several years of exploration, it has been able to produce Ф3500mm large circular saw blade base.
In view of the characteristics of mine cutting, Black Cyclone Saw Industry Co., Ltd. has three major technological breakthroughs:
1. Heat treatment method of the product: The heat treatment of such a large-sized saw blade base has no special equipment in China. We use a unique heat treatment process to solve the heat treatment problem of large-size and thin-thickness substrates, and the hardness is better. The control is in the range of HRC38±3, which improves the rigidity of the saw blade base and increases the service life of the product.
2. Processing method: Grinding of the end face of the saw blade is also a difficult point in product processing. We have developed a surface grinder and a lathe, which has solved this problem subtly. The thickness tolerance of the product can meet the requirements of national standards, greatly improving the static balance of the product, and removing the oxide layer from the surface of the material. The carbon layer, the fatigue life of the product is greatly improved.
3. In view of the fact that the saw blade is difficult to remove during the cutting process, the company has also made a bold exploration on the shape of the base: we use a number of hollow holes in the appropriate part of the saw blade base without affecting the saw blade. Under the premise of overall strength, the cooling and chip removal efficiency is improved, the service life of the cutter head is prolonged, the energy is reduced, and the mining time is shortened.
4. Comparison with economic and technical indicators of traditional mining methods
The application of new mining methods has increased resource utilization and mining speed, and the added value of products has increased correspondingly due to the improvement of mining quality. The production cost is reduced, and the shortcomings of the traditional mining methods, such as poor safety performance and serious environmental damage, have great economic and social benefits.
See the table below for a comparison of various mining forces.
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Fifth, the use requirements
1. Preparation before installation
(1) The laying of the sawing machine track requires that the sleeper is firm and flat, so as to avoid the shaking of the sawing machine during the cutting process. The parallelism tolerance of the sawing machine track is ≤5mm, and the horizontal tolerance is ≤2mm.
(2) In order to ensure the flatness and strength of the saw blade during the cutting process, the diameter of the flange of the clamping saw blade is > i280ram, and the unevenness of the flange directly affects the end jump of the saw blade. Therefore, the user should check the accuracy of the flange before use. Generally, the flange of the Ф280mm flange has an unevenness of <0.05mm, and the flange is clean and free of stone chips and dirt.
(3) Regularly check the accuracy of the saw shaft to ensure that the radial runout of the main shaft is ≤0.03mm to avoid the saw blade from vibrating during the cutting process, affecting the service life of the saw blade and the cutting quality of the material.
(4) The size of the cooling water directly affects the cooling effect of the saw blade, the chip removal capability and the cutting life of the cutter head. Therefore, it is recommended that Ф2000 (or Ф2200) cooling water ≥100 1/min, Ф2800 (or Ф3000) cooling water ≥160 1/rnin, and fully injected into the saw blade cutting joint.
2. Normative use
Due to the high price of the ultra-large diamond mesh saw blade, the standardized use can greatly increase the service life of the product and reduce the production cost, so the standard operation should be emphasized during the use of the product.
(1) The new substrate should be idling for more than 30 minutes before the first use, so that the stress distribution is more uniform by the centrifugal force of the saw blade substrate in the first use.
(2) Conditional enterprises should first open the blade before the new saw blade is used. Otherwise, when the new cutter head starts to be used, the required cutter amount is ≤l5mm/time, and the running speed is ≤l000mm/min. After the diamond in the cutter head is completely out of the blade, Can increase the amount of feed.
(3) During normal cutting, the amount of cutting is determined according to the hardness of the cutting object. (b2000 (or Ф2200) specification saw blade is controlled within 30~50mm/time, Ф2800 (or Ф3000) saw blade is controlled at 20~30mm In the second time, in order not to affect the cutting efficiency, the cutting process of shallow feed and fast cutter is made as far as possible, and the deformation caused by the excessive normal force of the saw blade base is reduced.
(4) In the cutting of the mine, the number of teeth involved in cutting by the saw blade is greatly increased due to the lowering of the knife at both ends, and the resistance is correspondingly increased. Therefore, when the lower knife is used, the jog and reciprocating cutting method should be adopted, and the amount of the lower cutting knife should not exceed 2 mm/time.
(5) During the use of the saw blade, the state of the cutting and the change of the hardness of the cutting object should be strictly monitored. When the working surface protrudes too much, the cutting depth and walking speed should be adjusted in time.
Conclusion
Mining the blocks with ultra-large diamond circular saw blades can reduce the mining cost by more than 20%, and the yield of the blocks can reach more than 90%. The mining method is simple, the floor space is small, the damage to the environment is small, and the mining blocks are regular. Therefore, it has great promotion value.
As everyone knows, I have a world of stone resources. In recent years, with the rapid development of the construction industry and the improvement of people's living standards, stone has become more and more popular with its unique natural attributes, and the demand for the market is increasing. In the same way, China's stone processing technology is close to the world's advanced level, but the mining technology of stone is still far behind developed countries.
At present, there are several main ways of mining in China: blasting operation, flame cutting method, expansion agent method, etc. The mining method generally has the disadvantages of low labor productivity, low yield, low waste of resources and poor safety. In recent years, some companies have used diamond bead wire saws and diamond chain saws for mining. Although they have achieved good results, they have large equipment investment and high mining costs. How to improve the quality and efficiency of stone mining, minimize damage to the environment, reduce the labor intensity of workers, etc., has become an urgent need to solve problems in the exploitation of stone blocks in China.
Second, the principle of cutting
In view of the above situation, Chinese scientific and technological personnel have skillfully applied the plate cutting mechanism to mining, and achieved good results. The basic principle is as follows: the track is laid on the mine table, and the super large diamond circular saw blade (Ф2000~3500mm) is driven by the host to rotate at high speed to realize on-orbit cutting. Due to the advantages of low investment, high efficiency, safety, environmental protection, energy saving and low mining cost, it is widely favored by mining enterprises.
Third, technical requirements
In addition to the good precision required for the sawing machine, the specification and quality of the ultra-large diamond circular saw blade are the key to this technology. As we all know, the size of the mining blocks is determined by the size of the saw blade. At present, the market requires the width of the sheet to reach about 1.5m. Therefore, the specifications of the diamond circular saw blades that match it must reach Ф3500 or more. At the same time, the field work environment such as the flatness of the mining operation, the cooling chip removal and the like are cut relative to the plate, and the conditions are even worse. Therefore, more stringent requirements are imposed on the manufacture of the saw blade substrate.
Yichang Black Cyclone Saw Industry Co., Ltd. has developed 矿山2300mm or more mining saw blade bases in 2003 according to market demand. After several years of exploration, it has been able to produce Ф3500mm large circular saw blade base.
In view of the characteristics of mine cutting, Black Cyclone Saw Industry Co., Ltd. has three major technological breakthroughs:
1. Heat treatment method of the product: The heat treatment of such a large-sized saw blade base has no special equipment in China. We use a unique heat treatment process to solve the heat treatment problem of large-size and thin-thickness substrates, and the hardness is better. The control is in the range of HRC38±3, which improves the rigidity of the saw blade base and increases the service life of the product.
2. Processing method: Grinding of the end face of the saw blade is also a difficult point in product processing. We have developed a surface grinder and a lathe, which has solved this problem subtly. The thickness tolerance of the product can meet the requirements of national standards, greatly improving the static balance of the product, and removing the oxide layer from the surface of the material. The carbon layer, the fatigue life of the product is greatly improved.
3. In view of the fact that the saw blade is difficult to remove during the cutting process, the company has also made a bold exploration on the shape of the base: we use a number of hollow holes in the appropriate part of the saw blade base without affecting the saw blade. Under the premise of overall strength, the cooling and chip removal efficiency is improved, the service life of the cutter head is prolonged, the energy is reduced, and the mining time is shortened.
4. Comparison with economic and technical indicators of traditional mining methods
The application of new mining methods has increased resource utilization and mining speed, and the added value of products has increased correspondingly due to the improvement of mining quality. The production cost is reduced, and the shortcomings of the traditional mining methods, such as poor safety performance and serious environmental damage, have great economic and social benefits.
See the table below for a comparison of various mining forces.
Fifth, the use requirements
1. Preparation before installation
(1) The laying of the sawing machine track requires that the sleeper is firm and flat, so as to avoid the shaking of the sawing machine during the cutting process. The parallelism tolerance of the sawing machine track is ≤5mm, and the horizontal tolerance is ≤2mm.
(2) In order to ensure the flatness and strength of the saw blade during the cutting process, the diameter of the flange of the clamping saw blade is > i280ram, and the unevenness of the flange directly affects the end jump of the saw blade. Therefore, the user should check the accuracy of the flange before use. Generally, the flange of the Ф280mm flange has an unevenness of <0.05mm, and the flange is clean and free of stone chips and dirt.
(3) Regularly check the accuracy of the saw shaft to ensure that the radial runout of the main shaft is ≤0.03mm to avoid the saw blade from vibrating during the cutting process, affecting the service life of the saw blade and the cutting quality of the material.
(4) The size of the cooling water directly affects the cooling effect of the saw blade, the chip removal capability and the cutting life of the cutter head. Therefore, it is recommended that Ф2000 (or Ф2200) cooling water ≥100 1/min, Ф2800 (or Ф3000) cooling water ≥160 1/rnin, and fully injected into the saw blade cutting joint.
2. Normative use
Due to the high price of the ultra-large diamond mesh saw blade, the standardized use can greatly increase the service life of the product and reduce the production cost, so the standard operation should be emphasized during the use of the product.
(1) The new substrate should be idling for more than 30 minutes before the first use, so that the stress distribution is more uniform by the centrifugal force of the saw blade substrate in the first use.
(2) Conditional enterprises should first open the blade before the new saw blade is used. Otherwise, when the new cutter head starts to be used, the required cutter amount is ≤l5mm/time, and the running speed is ≤l000mm/min. After the diamond in the cutter head is completely out of the blade, Can increase the amount of feed.
(3) During normal cutting, the amount of cutting is determined according to the hardness of the cutting object. (b2000 (or Ф2200) specification saw blade is controlled within 30~50mm/time, Ф2800 (or Ф3000) saw blade is controlled at 20~30mm In the second time, in order not to affect the cutting efficiency, the cutting process of shallow feed and fast cutter is made as far as possible, and the deformation caused by the excessive normal force of the saw blade base is reduced.
(4) In the cutting of the mine, the number of teeth involved in cutting by the saw blade is greatly increased due to the lowering of the knife at both ends, and the resistance is correspondingly increased. Therefore, when the lower knife is used, the jog and reciprocating cutting method should be adopted, and the amount of the lower cutting knife should not exceed 2 mm/time.
(5) During the use of the saw blade, the state of the cutting and the change of the hardness of the cutting object should be strictly monitored. When the working surface protrudes too much, the cutting depth and walking speed should be adjusted in time.
Conclusion
Mining the blocks with ultra-large diamond circular saw blades can reduce the mining cost by more than 20%, and the yield of the blocks can reach more than 90%. The mining method is simple, the floor space is small, the damage to the environment is small, and the mining blocks are regular. Therefore, it has great promotion value.
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