The wire rope diameter of diamond wire saw rope is usually 3 5-4. 9 mm, woven by 61~133 strands of wire rope. The diamond wire saw ropes for different purposes are sleeved with different circular diamond beads, and the beads are separated by plastic, rubber or spring. At present, diamond wire saws circulating in the market generally include 4 structures: 1. spring washer support and fixation (spring type), 2. polyurethane plastic injection seal (plastic injection type), 3. low-temperature resistant rubber injection seal (rubber injection type), 4. special type structure.
Diamond Wire Saw Rope with Spring Type Structure
Spring type diamond wire saw rope fixed by springs and washers can be generally assembled with electroplated diamond beads and hot-pressed sintered diamond beads. Springs and spacer washers are used as the spacing support between diamond beads to form a bead-cutting unit. The fixing ring fixes every 3-5 cutting units into a set of fixing units. According to the different lengths, select several groups of fixing units to assemble into a spring type diamond wire saw rope of the required length. The advantage of group fixation is to prevent the beads and other parts of the entire diamond wire saw rope from falling off once the wire rope is pulled off. At the same time, the diamond beads are separated and kept in several cutting unit groups. The diamond beads are reasonably gathered in each group, preventing the diamond beads and other parts from gathering together under the effect of cutting resistance.
The spring type diamond wire saw rope adopts an open structure. The springs between the diamond beads are assembled after preloading. The diamond beads, spacer washers and springs in each fixed unit group always move back and forth on the wire rope during the cutting process. During the cutting process, the diamond beads rotate with the rotation of the wire rope, while maintaining the relative rotation between the two parts, so as to make the diamond beads wear evenly in all directions along the circumference surface and ensure the maximum service life of the diamond beads. Therefore, when the spring type diamond wire saw rope is connected to a closed ring, there is no need to rotate and load the diamond wire saw rope in advance, and the connection mode is simpler. However, when cutting granite, hard particles such as quartz will fall between springs, seriously eroding the bead framework and steel wire rope, causing premature wear and a scrap of the inner ring of diamond beads, as well as damage and fracture of steel wire rope. Therefore, the spring type diamond wire saw rope can only be used for the mining and cutting of soft stones such as marble and limestone, and cannot be used for the cutting of hard stones such as granite.
The early stage spring type diamond wire saw rope had no spacer washer, and the spring directly contacted the framework of the diamond bead and wore the framework of the diamond bead, which easily caused premature wear and a scrap of the diamond bead. At present, the spring type diamond wire saw rope is added with a spacer washer on the basis of the early spring diamond wire saw rope. The spring can only wear the spacer washer in the process of compression and release, and will not damage the diamond beads, thus prolonging the service life of the diamond beads. If the washer is damaged in advance, it only needs to replace with a new one, the diamond wire saw rope can be used again.
Diamond Wire Saw Rope with Plastic Injection Type Structure
Plastic injection type diamond wire saw rope is actually a kind of diamond wire saw rope structure developed for cutting hard stone. Usually, hot-pressed sintered diamond beads are used, and the special polyurethane plastic with high-temperature resistance and corrosion resistance is used as the spacing support of diamond beads. The diamond beads and steel wire rope are fixed by hot-pressed injection plastic. This is a sealed diamond wire saw rope structure. The gap between the diamond beads and the steel wire rope is filled with polyurethane plastic to prevent debris generated during the cutting stone. It can be used for cutting granite and other hard stones. However, the plastic injection type diamond wire saw rope also has its defects, such as its poor low-temperature characteristics. When it is used in cold regions, because the plastic injection layer becomes stiff, the internal stress of the diamond wire saw rope increases during cutting, and the probability of wire rope breakage increases. In addition, the plastic injection diamond wire saw rope has higher requirements for the supply of cooling water. A short time of water shortage or insufficient supply of cooling water may cause the plastic injection layer to become soft or even melt, making the diamond wire saw rope scrapped.
Diamond Wire Saw Rope with Rubber Injection Type Structure
Spring type and plastic injection type diamond wire saw ropes have different characteristics, and rubber injection diamond wire saw ropes combine the advantages of both. Its structure is the same as the plastic injection diamond wire saw rope, and it is also a sealed structure. However, special rubber materials with soft, wear-resistant and better low-temperature performance are used as isolation and filling materials between beads and between beads and wire ropes. Rubber injection diamond wire saw rope has good flexibility, especially when used in low temperature and cold areas, it can still maintain the good flexibility of wire rope, so it is a special diamond wire saw rope suitable for cutting hard stones under low temperatures. When using rubber injection type diamond wire saw rope for cutting, it is also necessary to maintain a good cooling water supply to prevent excessive wear of the rubber layer.
With the improvement of injection sealing technology and the reduction of plastic injection and rubber injection costs, plastic injection and rubber injection diamond wire saw ropes are also used for marble mining and cutting. If electroplating diamond beads are used, the sharpness and self-sharpness of electroplating beads can be maintained, and the danger of using spring type diamond wire saw rope can be avoided. If the cutting cost is allowed, sintered diamond beads can also be used to extend the service life of diamond wire saw ropes. Therefore, it is also the most reasonable choice for marble cutting to use electroplating or sintering diamond beads, plastic injection and rubber injection diamond wire saw ropes.
Diamond Wire Saw Rope with Special Type Structure
Diamond Wire Saw Rope for Reinforced Concrete Cutting
When plastic injection or rubber injection diamond wire saw ropes are used to cut reinforced concrete, in order to compensate for the strength of the diamond wire saw ropes when cutting the reinforcement framework, the support springs are added between the diamond beads to improve the spacing support strength between the diamond beads. The same structure can also be used for diamond wire saw ropes for stone cutting.
When cutting masonry structures and plain concrete structures without reinforcement, because the strength and hardness of the components to be cut are very low, in order to improve the cutting efficiency, increasing the sharpness and self-sharpness of diamond beads has become the main requirement. Therefore, on the premise of not changing the structure of wire rope, electroplated diamond beads with good self-sharpness and high cutting efficiency can be used, then the support springs are added between diamond beads, and a layer of plastic or rubber is injected on the spring surface.
When cutting reinforced concrete components, in order to improve the cutting life of the diamond wire saw ropes, special diamond sintered beads shall be used, and the structure of diamond wire saw ropes with plastic injection or rubber injection sealing shall be used.
Diamond Wire Saw Rope with Special Shape Injection Layer
For the common diamond wire saw ropes in the market, the injection layer is smooth, but due to the special function needs, some injection layers of diamond wire saw ropes are designed into special shapes.
For example, the injection layers of some diamond wire saw ropes are made into regular bulges and grooves. In addition to plastic encapsulation and spacing of diamond beads, the grooves can improve the carrying capacity of cooling water. The bulges can take away more rock-cutting debris, and improve the cooling and chip removal capacity of diamond wire saw ropes, thus improving the cutting speed, reducing the wear of diamond wire saw ropes, and increasing the cutting life of diamond wire saw ropes. Another is to wrap the injection layer outside the springs and make it into a spiral shape, which is used to reduce the friction resistance during cutting. A small amount of water can eliminate more stone chips.
Conclusion
The 4 structures of diamond wire saw ropes have different physical properties, which also means that different structures will adapt to different cutting scenes. The cutting efficiency and service life can be improved only if the proper diamond wire saw ropes are selected and used correctly.
