Stone block cutter is an equipment that has been widely used in stone processing industry. Most stone processing plants have ever experienced some problems with their stone block cutters. For example, unstable performance, machine body shakes when it go up and down, segments consumption too fast, slab surface cut by the machine is not flat, working efficiency is too low, etc. So we can see it that a reasonable and effective maintenance to the machine is helpful for improving production efficiency and product quality.
When the machine turns out to be unstable performance, vibrating or fail to up and down, we can make an analysis from the following 3 aspects.
1) Problems may occur to the stone saw machine.
Fixing bolts get loose in the machine body, speed reducer is out of lubricating oil, gears worn out and bearings break out, spindle radial run out due to too big or too small space between bearings, flange for fixing blade on the spindle is deformed, no enough lubricating oil in the guide rails for machine movement or the lubricating oil is too thin or too thick, rolling wheels press too hard on the rails, cycloidal pin gear speed reducer is broken.
2) Problem may occur to the blade
Too big radial run out in new saw blade, blade central hole and the spindle is not concentric circles, diamond segment is not sharp enough or not suitable for the stone it is cutting, the blade has been welded segments for recycle usage too many times.
3) Problem may occur to the operation
The block trolley is not firmly locked, blade horizontal forwarding speed is too fast, blade vertical feeding depth is too much.
Ways to solve the problems mentioned above.
Pay more attention to the granite saw machine spindle box. Check to find out if the spindle radial run out is beyond acceptable range. If the spindle radial run out is out of acceptable range, adjust bearing pressing bolts to recover it.
Check to find out if the bearings, gears, blade spindle and bearing spindles are in good condition. Evaluating their wearing extent to make decision whether to replace or repair them.
Check to find out why the speed reducer box is out of lubricating oil. If it is caused by the failure of sealing ring, replace it by a new one.
Check to find out if the fixing bolts on the machine body are tight or loose. If getting loose, tight them again.
Check to find out if the machine has enough lubricating oil in the guide rails, if not, add more oil for it.
We all know that diamond circular saw blade plays a very important role in stone cutting works. Choosing the right diamond circular saw blade can improve block cutter machine capacity by 5% and reduce production cost. Most people like thin circular saw blade. So they can use thin segments as well. Even though that the thin circular saw blade costs a bit higher, they can reduce more cost in segment and electric power, and get more slabs from a stone block. There are 5 tricks for better use of the diamond circular saw blade in block cutter machine.
1. Sharpness Comes First.
The hardness of diamond grits on the circular saw blade should have higher standard than that of normal diamond grits.
The percentage of 40/50# coarse diamond grits account for 60% at least.
The concentration of diamond grits no more than 25% in the segment.
Segment made by low temperature metal binder formula which enables the segment to be sharp and diamond grits not easy to drop off.
Shorten the segment length to 21mm.
2. Smaller Motor Power
The saw blade gets thinner, its rigidity gets lower accordingly, so the saw blade’s friction force during cutting process also gets smaller.
The segment gets thinner and shorter, it faces smaller drag force in cutting process.
The diamond circular saw blade is sharper with higher cutting capacity.
So, if the original motor power is 30kw, now it can be changed to 22kw. The electricity currency controlled to be 35A. Production capacity will keep in the same level.
3. Control the Heat Impact
In welding diamond segments onto the circular saw blade, it is better to use the low temperature silver sheet. The low temperature silver sheet requires short time heating and has small heating impact to the neighboring segments. It’s recommended to keep a distance between the former and latter welding, for example, a distance of 6-8 teeth. When the first round is finish, resume the next round.
4. Operation Techniques
In the beginning of stone cutting, the blade should forward slowly, vertical blade feeding should shallow. When the blade has cut a 30mm deep slot in the stone, then the blade forwarding speed can be higher and blade vertical feeding can be deeper.
Use small circular saw blade first, then comes the bigger saw blade. If you are cutting 600mm width slab from stone block, you can use the dia.1600mm blade to cut directly. If you are cutting 800mm width slab from stone block, you can use the dia.1600mm blade to cut 600mm deep first, then change to dia.2000mm blade to cut the rest 200mm deep.
Execute reasonable blade forwarding speed and vertical feed depth according to the degree of stone hardness. If the stone is very hard, the blade vertical feeding should be shallow and horizontal blade forwarding speed should be fast.
Always rotate the diamond circular saw blade in the same direction for stone cutting. Otherwise the saw blade may be easy to get “tired” and break.
5. Protection Measurement
The thin circular saw blade turns to severe deformation once be sucked by stone. Though that the saw blade can be leveled again after deformation, its quality and service life will be greatly impacted. So it is necessary to take some protection measurements on the multi blade block cutter machine once the blade is sucked by stone.
