Current status of domestic stone processing saw blade base technology

In recent years, the number of synthetic diamonds used in the stone processing industry has risen linearly, and its consumption accounts for about 90% of the total production of synthetic diamonds in the country. The domestic diamond saw blade matrix is ​​also mainly used in the stone processing industry.

According to the classification of materials, the materials for the domestic production of diamond saw blades are mainly made of 50Mn2V, 75Crl and 65Mn. Some low-end markets also use 45# steel. 45# steel is ordinary carbon steel, 65Mn is ordinary spring steel, and 75Crl is high carbon alloy steel. In comparison, 50Mn2V is a medium carbon alloy steel with 50Mn2V fine grain, high thermal stability, high toughness, fatigue resistance and heat resistance. The saw blade base of 50Mn2V material has the advantages of many times of re-welding, long service life, easy deformation of the saw blade after welding, and easy repair after deformation. The product also has the effect of gradually increasing the rigidity during use, so 50Mn2V Materials are widely used in the processing and production of diamond saw blade substrates.

According to the classification, the specifications of the domestic stone processing saw blade base start from Ñ„200mm, and the maximum is Ñ„3500mm (the specification of the largest circular saw blade in foreign countries is 5000mm). Among them, dp 200-600ram specifications are mainly used for trimming (trimming) processing of semi-finished sheet; Ñ„650 and above specifications are mainly used for forming sawing of thick stone slabs (columns) such as tombstones and tombs, and for cutting materials. Sawing into (board) processing. At present, the Ñ„1600mm saw blade substrate is most commonly used.

Ф200～600mm specification saw blade base, due to low technical content, the technical and quality requirements of the product are not high, only the ability to trim the edge is required, and the products on the market tend to be homogenized. At present, there are nearly 100 manufacturers of saw blade bases in China, and the market competition is mainly based on price competition. The industry is fiercely competitive and the profits are very low. Some domestic powerful enterprises do not intend to participate in this low-end market competition.

The base of Ñ„650mm or above is relatively difficult to process with respect to Ñ„200-600mm. The industry has more initial capital and higher threshold. The quality requirements and performance requirements of the product are also high. At present, there are not many domestic manufacturers, less than 10, and the products show a certain degree of difference. The market competition is based on non-price competition. The quality of the products themselves, the stability of performance, the length of life and the quality of service are good. Play a key role in market competition. In the southern regions of Fujian and Guangdong, diamond saw blade substrates are generally used in groups, such as Ñ„940mm species Ñ„l600mm each of 10 pieces of each combination, Ñ„680mm, Ñ„ll40mm and Ñ„l600mm each use 5 pieces each combination. The combined saw blade base is used for cutting granite and marble plates in groups, which greatly improves the cutting efficiency and plate precision, saves electricity consumption by more than 15%, and also puts higher quality and performance requirements on the saw blade base itself.

As the country pays more and more attention to environmental protection, the shortage of mine resources is scarce, the supply of power resources is tight, the manufacturing costs of stone enterprises are rising, competition is intensifying, and some energy-saving, resource-based and environment-friendly saw blade substrates are increasingly being marketed. Welcome, customers have some new features for the variety of saw blade base:

1. Sheet, ultra-thin saw blade substrate

The sheet and ultra-thin saw blade base are mainly distinguished by the thickness of the base. For the Ñ„1600mm base, the normal thickness is 7.3mm, the thickness is below 6.5mm, which is called the sheet base, and the thickness below 5.5mm is called ultra-thin. Sheet base. Cutting granite and marble plate with sheet and ultra-thin saw blade base can greatly improve cutting efficiency and raw material yield, and reduce power consumption. For example, using Ñ„1600mm ultra-thin substrate with thickness of 4.0mm can improve cutting efficiency by more than 10%. Reduce electricity consumption by more than 20% and increase the utilization rate of block materials by more than 16%.

Since the thin and ultra-thin diamond saw blade has a thin thickness and a large diameter and a large deformation during heat treatment, the heat treatment process is very important for the control of flatness and HRC. At the same time, due to the thin thickness, the adjustment of the end jump and the stress, including the detection, are extremely difficult. Under normal circumstances, it is difficult to achieve good results by manual leveling and detection alone. The domestic four-in-one advanced equipment imported from Germany, which integrates rolling, adjusting stress, detecting end jump and flatness, is specially designed for the production of ultra-thin circular saw blade base, which better solves the product stress distribution. Problems with the flatness, end jump, rigidity and other indicators of the product.

2. Frame saw blade base

Diamond frame saw, also known as diamond saw, is a new type of frame saw machine that was developed in the 1950s. At present, in the stone industry, the diamond frame saw frame has basically replaced the sand saw on the processed marble. The advantages are: high cutting speed and high production efficiency; good processing quality, smooth and flat sawing plate, can be omitted A rough grinding process; saving labor and steel, improving the working environment and facilitating management.

At present, diamond frame saws have been promoted and applied in China's marble sawing, especially in Guangdong, Fujian, Shanghai and other places. It is understood that the total capacity of the saw machine has reached more than 700 units. A large amount of domestic data proves that some technical and economic indicators of diamond frame saws are partially better than sand saws. With the advancement of domestic cutter heads and saw blade bases, diamond frame saws can partially replace sand saws.

The cutting mechanism of the diamond saw blade diamond frame saw is through the reciprocating linear motion of the frame, and the cutter head crushes, cuts, wipes, furrows, crushes and grinds the blocks to cut the blocks. Due to the short stroke, low line speed, small amount of water, and difficult chip removal, high demands are placed on the sawing machine, the cutter head and the base. Under the current circumstances, the sawn granite frame saw blade matrix still relies mainly on imports, but the domestic black cyclone company has begun to develop, produce, and establish a high-level professional production line, steel selection and international standards, most of the main indicators It can reach the standards of advanced countries such as Germany, France, Belgium, etc. The products produced will gradually replace imports and begin to export in batches.

3. Very large saw blade base with a diameter of 2600mm or more

At present, there is still a backward method of mining and shooting stones in the country, which is not only low in production efficiency but also unsafe in operation. Especially, the rock mass is broken due to knocking, the stone resources are seriously damaged, and the size of the blocks is produced. Irregular, even scrapped due to cracks, the yield is very low. It is estimated that only 5% to 25% of the mined material can be processed into materials by means of eye-blasting. Some stone industry developed countries have banned the use of explosive blasting methods to mine stone. The international industry believes that China's stone mines have low productivity and serious waste of resources. The main reason is the lack of corresponding large-scale industrialization of diamond saw blade substrates and related mechanized equipment. Mining technology is backward and production management is not good.

In recent years, China has taken the lead in research and development of a large-scale mine hollow saw blade base. Some mining companies use large scales of Ñ„2600mm or above to mine, and the utilization rate of mine resources reaches 90%. According to research, at present, the use of super-large saw blade matrix for the mining of stone blocks has been paid more and more attention and promotion, and the number of mine sawing machines has rapidly increased to 800 units.

In addition, the market demand for stone slabs is getting larger and larger. In the past, it relied mainly on frame saw blades to process stone slabs. However, diamond frame saw blades are mainly suitable for cutting soft stones such as marble. For the cutting of granite and craft stone, it still needs to be cut. Circular saw blade to complete. In order to meet the requirements of domestic and foreign markets, stone processing enterprises will use a large circular saw blade to cut large plates, which will have a peak in recent years.

4. Hollow saw blade base

Compared with the conventional saw blade base, the hollow saw blade base has only a plurality of rows of holes processed on the base body, and the shape of the holes is mainly water droplet type. From the current use of Ñ„l600mm hollow circular saw blade, the sawing process does not change any stone with Mohs hardness below 7 degrees. The hollow saw blade base exhibits the following advantages compared with the conventional base. : (1) easy to enter the water, significantly improve the cooling effect; (2) increase the amount of chip removal; (3) reduce the weight of the substrate and the running load of the saw machine, the current is reduced by 5A; (4) reduce the running noise (5) Due to the weight reduction of the base body, it is possible to load more diamond saw blades by the small combination saw machine; (6) It can extend the service life of the base body, increase the number of square meters to be cut, and have small welding deformation; (7) Use intermittent, tension Good recovery performance. From a large number of use data, the use of hollow saw blade base for processing stone can not only greatly reduce the power consumption per square meter, but also improve the utilization rate of stone block resources and improve the labor productivity of stone processing. At present, the hollow saw blade base is not only widely used in the field of stone processing, but also in the field of stone mining, the super large hollow saw blade base of Ñ„2600mm or more is getting more and more popularized.

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