Energy saving by prediction of the optimum cutting rate in stone cutting process: An industrial scale study

Abstract

Sawing of rocks cost is controlled to a large extend by the cutting rate which is influenced by the properties of the saw and the sawn rock. Energy consumption is very important unit cost parameter, which strongly depends on cutting rate, in stone cutting process. In this study, in order to find the optimum cutting rate for Karacadag basalt units, primarily the properties of the basalts from four different regions were determined. After that, cutting experiments were carried out in three stages on four types of basalt units in a marble cutting plant with a special saw that is only used for cutting basalt. Based on specific energy, optimum cutting conditions were determined. It was found that the optimum cutting rate changes depending on the rock unit, cutting depth and the saw diameter. Optimum cutting rate, cutting depth, saw diameter and rock properties were evaluated using multiple regression analysis and models were developed. It was concluded that the optimum cutting rate can reliably be estimated using one of the developed models which were included cutting depth, saw diameter; and some rock properties, such as uniaxial compressive strength, Young's module, cohesion, Poisson's ratio and Schmidt hardness. © Sila Science.