Investigation of rock cutting performance of disc cutters and development of models for performance prediction

In this study, sawability analyses of granitic rocks were carried out using disc cutters. Cutting force, specific energy, specific wear in discs, roughness of wearing rock surface and noise level generated during cutting were based as performance indicators. Effects of each cutting parameters on the cutting performance were determined and the cutting performance were correlated with the rock properties by various approaches. Models were built for the estimation of the cutting performance depending on the cutting parameters and the rock properties. Validation of the models was checked by various analyses. Additionally, SEM images of wearing surfaces of the segments and the rocks were analyzed. It was determined that effects of cutting parameters on the cutting performance show differences for each performance indicator. It was also concluded that rather than the physico-mechanical properties, the mineralogical properties were mainly responsible for the cutting performance (excluding noise level). Emerging, fractured, polished and pulled out crystals were determined in the wearing surfaces of the diamond grits. Fractured, pulled out particles and cutting marks were observed as the characteristic features of the cutting method. It was revealed that sawability of granitic rocks could be predicted by the models developed without conducting cutting tests including complex experimental procedures.