Investigation of diamond segments used in natural stone industry in view of cutting performance and failure analysis

This study undertakes an experimental and theoretical examination of the cutting performance of diamond cutting disc used during the natural stone cutting process. A computer controlled block cutting machine was used during the cutting experiments and the preferred method had been the same-direction cutting method. The Blue Pearl and Nero Zimbabwe granite were used in the study. Firstly, variation tests were performed using a type diamond segment and different cutting parameters and optimum cutting parameters are determined. Then, the variation tests carried out to eight different diamond segments and cutting performance of each diamond disc was determined. Normal and tangential forces, axial forces, specific energy, power consumption and noise values were determined in the variation and the performance tests. The wear occurring on the diamond segment was measured using a laser measurement device and the damage occurring on the segment surface was determined using optical microscope and SEM analysis. While water was preferred during the variation and performance tests of the disc, this study also examined the effect of various coolants on the disc performance. For this purpose, four different types of coolants, namely water, boron oil, a special cutting fluid designed for the diamond and liquid soap, were used after mixing it with water at a specified proportion. In this study, a new measurement system was developed to determine the heat generated on the segment surface during the cutting process. Temperatures effect on the diamond segment were determined with the measurement system. Wet and dry cutting tests were conducted at different cutting parameters for the two granite types using a disc, which was designed specifically for measuring the temperature. In theoretical study, the diamond particle was modeled by finite element method take in to account failures obtained using optic and SEM.