Stone Cutting Machine

How To Use A Diamond Wire Saw?

Table of Content

ONE. Requirements for the working environment before the product is used

1. Power requirements: provide a three-phase power supply of 380±10%V, and provide enough length according to the actual situation of the site
degree of cable.
Cable specifications: (1) 22kw, 30kw: YC3×16+1×10; (2) 37, 45kw: YC3×25+1×10; (3) 55, 75kw: YC3×35+1×16.
2. Ensure that sufficient cooling water is supplied, and prepare 2-3 water supply pipes and water flow switches that can control the flow.
Cooling of the wire saw during sawing work. The water supply capacity is not more than 0.35t/h (700kg).
3. Prepare a 2m x 6m flat site near the stone to be cut for placing the wire saw track.
4. Prepare suitable lifting equipment such as cranes, loaders, excavators, etc.
For immature mines, the use of reed cranes and chain hoists of more than two tons can be considered for hoisting.

5. Prepare other necessary tools according to the actual situation.

TWO. Rock drilling

Since the working principle of the wire saw is that the wire saw is driven by the Diamond wire saw machine to rub against the stone to be mined for wire cutting to achieve the purpose of cutting, so the block should be opened before mining. The following two methods will be used. Take common mining forms as an example, and describe the method of punching.

1: Vertical cut

The white line in the figure is the opening direction. There are two holes in total, one is a vertical hole and the other is a horizontal hole. When the two holes are punched, they intersect so that the wire saw can intersect from the two holes. through the hole.

2: Horizontal cutting

However, in actual operation, the vertical hole and the two horizontal holes will be opened in advance, and the three holes will meet together, and the horizontal cutting will be started first. If the vertical cutting is done first, after the vertical cutting is completed, the horizontal cutting will be pressed down due to the weight of the stone, so that the horizontal cutting can no longer be completed. This has the following advantages: ① When the horizontal cutting is done first, the vertical holes can be used as cooling water ② If the vertical hole is opened after the horizontal cutting is completed, it will increase the difficulty of threading the wire saw during vertical cutting. ③④

3. Use an air pick (pneumatic drill) to open the hole

As with vertical cutting, the horizontal white line is the opening direction, and the two horizontal openings meet together, and then the wire saw is pierced along the two holes to start cutting.
However, in actual operation, the vertical hole and the two horizontal holes will be opened in advance, and the three holes will meet together, and the horizontal cutting will be started first. If the vertical cutting is done first, after the vertical cutting is completed, the horizontal cutting will be pressed down due to the weight of the stone, so that the horizontal cutting can no longer be completed. This has the following advantages: ① When the horizontal cutting is done first, the vertical holes can be used as cooling water ② If the vertical hole is opened after the horizontal cutting is completed, it will increase the difficulty of threading the wire saw during vertical cutting. ③④
3. Use an air pick (pneumatic drill) to open the hole
Drilling with an air pick is the most economical way to drill and it is one of the must-have tools for all mines. Its speed varies according to the hardness of the stone, generally between 3-5 meters per hour, its price is low, the success rate of drilling is also above 60%, and the success rate of skilled workers can reach 80%. When using an air drill to open a hole, be careful not to open the hole while flushing with water, because the sediment will block the hole. beat.
When punching holes, pay attention to the intersection of the horizontal and vertical directions, as shown in the figure:

First make a straight hole in the vertical direction, then set up a straight rod, pull it down with a pull rope and also set up a straight rod, use the vertical line of the hanging wire as the coordinates of the horizontal hole, and open the hole straight. The horizontal holes are drilled, and then the vertical straight holes are opened, which should be arranged freely according to the site conditions. Be sure to level with a level ruler when opening the hole.

THREE. Installation Of The Wire Saw

1. Before installing the wire saw, confirm the direction of the wire saw, and make sure that the direction of the arrow on the wire saw is consistent with the cutting direction. Some used ropes cannot see the direction of the arrow on the rubber. You can identify the direction of the wire saw according to the direction of the diamond particles on the beads. Insert the wire saw through the drilled hole in the surface to be cut. Note: When cutting the vertical surface, the running and running direction of the wire saw must be in the horizontal hole and pass through the vertical hole. When cutting the horizontal plane, determine the penetration direction according to the actual position. The running direction of the wire saw should be consistent from new to old. If worn backwards and used, the entire wire saw may be billed.
2. Do not mix the new rope with the old rope, which will cause a lot of waste, and also cause the accident of rope jam and broken rope.
3. The wire saw must use a special wire saw joint (gift) when connecting. Remember to connect the wire before connecting.
The saw is rotated for a certain number of turns in advance, the rotation direction is counterclockwise, and the number of turns is 1 to 3 (circles/m). The degree of use, gradually increase the number of torsion turns, at most 3 turns/m, too much will cause the wire rope to fatigue, cause the beads to move, and the wire saw will be charged. Use hydraulic crimping pliers to connect the wire saw that has rotated a certain number of times with a special joint, and prepare to surround it on the drive flywheel of the wire saw machine.

FOUR. The Installation Of The Guide Wheel

1. When cutting a larger cutting surface, install the guide wheel as shown in Figure 4 and fix it firmly. all guides
The wheel, driving flywheel, beaded rope and the surface to be cut should all be in the same plane.

Guide wheel installation diagram
2. When cutting the vertical cutting surface, install the guide wheel as shown in Figure 5. The guide wheel cuts in the initial position
After cutting for a period of time, according to the actual situation, move the guide wheel to the middle position in time and re-fix it firmly to avoid the beaded rope cutting the guide wheel bracket.

Schematic diagram of guide wheel installation when cutting vertically
3. When cutting the horizontal cutting surface, install the guide wheel as shown in Figure 6.

FIVE. The Installation Of Diamond Wire Saw Machine

1. Installation of the rail: Install the guide rail at a distance of about 1-3m from the front end of the surface to be cut. The guide rail must not have obvious distortion after installation and during operation. The guide rail can be guaranteed by placing wood and stones under the guide rail. The ground is evenly contacted to ensure that the working surface of the guide rail has no obvious levelness error, and the guide rails on both sides have no obvious straightness error. The feed rollers between the two adjacent guide rails should be connected accurately and firmly. Use connecting pieces to connect. After the guide rail is installed, make sure that the guide rail on the side of the driving flywheel and the surface to be cut are basically in the same plane. Remember that the track must be parallel to the rock face to be cut, otherwise an isolated face similar to the bottom of a pot will be cut, wasting resources.

2. Use suitable hoisting equipment (cranes, loaders, excavators, etc.) and tools (wire ropes, slings, rings, etc.) to hoist the wire saw to the guide rail closest to the cutting surface. Carefully check each connection before hoisting Whether the part is firm or not, it must be kept stable during the hoisting process, and must not collide with other objects, especially the main flywheel part, to ensure safety.

3. After the wire saw machine is installed in place on the guide rail, place the operating table at a suitable position about 6-10m away from the side and rear of the wire saw machine, so that the operator’s line of sight is required to clearly observe the operation of the wire saw machine.


4. After the installation is completed, connect the main cable and the control cable, and the connection is required to be firm and not loose.

5. Loosen the lock nut of the guide wheel connecting rod on the wire saw machine, adjust the guide wheel to the proper position, put the wire saw on the main flywheel, and make the wire saw have a large enough wrap angle on the driving flywheel. There is a suitable cutting angle on the cutting surface, and then the guide wheel connecting rod is locked and ready to start cutting.

4. Before penetrating the wire saw, the corner edge of the surface to be cut should be manually trimmed into rounded corners (top surface when cutting vertically, and on the side when cutting horizontally). The inner corners are pre-ground and smooth to ensure that the wire saw moves flexibly in the intersection hole without jamming.

5. Turn on the cooling water source, spray the cooling water on the wire saw and confirm that the cooling water enters the cutting surface before starting the wire saw machine for cutting. When cutting vertically, the cooling water nozzle must be moved as the cutting position of the wire saw changes. When cutting horizontally, the cooling water addition point at the horizontal orifice moves with the saw seam, and the water addition point at the vertical orifice is generally temporary, and can be canceled when the saw seam is far from the vertical hole. The amount of cooling water should be appropriate. Too little water will burn the injection molding layer of the wire saw. Too much water will cause the wire saw to slip or polish. Keep no dust sprayed during cutting, and the sprayed water is mist and water vapor. .

6. Carry out normal sawing operations as follows:

(1) Press the “Control Power” start button on the console, and the “Power Indicator” light will be on.

(2) Turn the “Manual/Auto” selector switch to “Manual”.

(3) Turn the “Main Motor Direction” selector switch to “Forward” or “Reverse”, and slowly adjust the “Main Motor Speed ​​Control” knob. When cutting, the speed should be slow to avoid damage to the wire saw by the edges and corners of the stone. After cutting for a period of time, it can be properly accelerated, and the display or digital meter will display the wire saw speed and current information in real time.

(4) Turn the “feed direction” selector switch to the “reverse” gear, and slowly adjust the “feed speed control” knob to make the wire saw reach the appropriate tension, then the main motor current display value will gradually increase .


(5) When it feels that the tension of the rope is appropriate and the current of the main motor is relatively stable, turn the “manual/automatic” selector switch to the “automatic” gear, and the wire saw machine will automatically run according to the selected program and according to the actual operation. The feed speed is automatically adjusted according to the situation, and it is most suitable to keep the line speed at 20-25 m/s. For example, for WS37 series models, the diameter of the main flywheel is 800mm. After using the automatic program, the wire saw will always maintain a constant cutting force to ensure the best cutting speed and effect. If you feel that the tension of the rope is not appropriate, you can modify it in the parameter setting column of this display to achieve the best cutting effect. Using the model of the instrument, you can adjust the tension adjustment knob to achieve the appropriate cutting tension. Maintaining the proper tension has a good effect on the service life and cutting efficiency of the wire saw.

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7. When the wire saw machine is about to run to the end position on the guide rail, as long as the site conditions permit, the method of replacing the front and rear guide rails should be used to continue the sawing operation. Only when the site conditions do not allow, the method of moving the machine and cutting the rope can be used to continue the sawing operation, so as to avoid waste of the wire saw. 8. When the sawing surface is only about 2 to 3 square meters, it is recommended to replace an old wire saw whose beading has been excessively worn and is about to be scrapped, but the mechanical properties of the wire rope are good and continue to cut. If the guide wheel is properly installed, the remaining surface can be cut through, or when about 0.3 to 0.5 square meters left, stop cutting and take other methods to separate it.

9. In order to ensure that the cutting surface is flat, appropriate measures should be taken to correct the cutting trajectory in a timely manner to ensure that the driving flywheel, the wire saw and the cutting surface are completely in the same plane.

10. When cutting a working surface or need to stop temporarily, turn off the wire saw machine according to the following steps:

(1) Turn the “Manual/Auto” selector switch to “Manual” first.

(2) Turn the “feed speed control” knob to the minimum position, and then turn the “feed direction” selector switch to “stop”.

(3) Rotate the “Main Motor Speed ​​Regulation” knob to the minimum position, and then turn the “Main Motor Direction” selector switch to the “Stop” position. When stopping in the middle, after turning off the travel switch, you should wait for 10-20 seconds before turning off the main motor, which is convenient for the next startup.

(4) Turn off the power switch after the inverter and the main motor are completely stopped.

11. When the wire saw machine is in the sawing operation, if there is a fault, the fault indicator on the operating table will be on, and the current fault will be judged and eliminated in time. If it is a frequency conversion fault, press the “frequency conversion fault reset” button. 12. In case of emergency during work, you can press the “emergency stop” button; if you need to re-operate, just reset the “emergency stop” to continue the operation.

More about our Diamond Wire Saw Cutting Machine knowledge. Please check out Diamond Wire Saw Cutting Machine product catalogue

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