diamond wire saws
TRANSCRIPT
WIRE SAW TECHNOLOGY
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Wire saw technology
WIRE SAW TECHNOLOGY
The new dimension in flexibility and economic efficiency
Diamond wire saws open up new applicationsNearly unlimited wall thicknesses, the most widely different materials,different cutting guides.Highest flexibility with the positioning of the machine.Ideal with limited amount of space.
The application of TYROLIT wire saws offers the following advantages:• Convincing performances through robust construction and high-
quality raw materials• Under normal conditions, wire breakage can be as good as
excluded• High flexibility and at the same time complete protection through
special rubber- or plastic coating, no corrosion of the carrier wire• High cutting performance, already in new condition, because of
pre-sharpening, time saving right from the start• Optimum water transport through ideal shaping, damage through
overheating (by sufficient water supply) is as good as excluded because of this
• Different specifications, adapted to different materials• System accessories for optimum function• Optimized connection system for the avoiding of wire breakage
Design of the wire saw:
Carrier wire: Fine stranded steel wire with high strength Book load approx. > 19.000 NDiamond ring: Cutting element – like segments with sawsCoating: For fixing the diamond rings on the carrier wire and protection the carrier wire from
corrosionReinforcing spring: For protecting from damage (sliding) and spacers with spring wiresConnection: For connecting the wire ends
Reinforcing spring
Carrier wire Coating Running direction
Connection Diamond ring
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Application hints:
• Pay attention to stable mounting of machine and deflection rollers• Pay attention to the running direction of the wire (arrow) or supporting
wedge of the bond, cone shape of the bead• Twist wire to the left, in order to guarantee an even wear• Avoid wire length under 7 m – too short lengths lead to out of the round
wear of the beads• Round off corners on the workpiece before start of operation, in order to
avoid jamming = Danger of damage• Pay attention to adequate water supply, set optimum water nozzles• Start the wire without load, in order to avoid jamming – if possible with
very reduced wire speed• Wire speed should amount to 16 – 25 m/s, higher wire speed = greater danger of wire breakage• Work with reduced feed pressure by short wire contact lengths – otherwise the high contact pressure
leads to strongly increased wear• Never use wires with a diameter difference of more than 0,2 mm together (the result is jamming in the
cut)• Keep absolutely to safety distances and use protection equipment, in order to avoid an endangering of
persons by a possible wire breakage, see manufacturer’s operating manual• Store wire dry and away from sunlight, in order to avoid corrosion of the carrier wire and brittleness of
the rubber – rusted wire leads to breakages
Sintered diamond impregnated ring = multi layered
Electroplated diamond layer = single layered
Thread
Steel carrier
Carrier: steel body with internal thread for good fixing to carrier wireCutting layer: in sintered or electroplated bonded design
Design of the diamond rings (beads):
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Wire saw technology
Twisting of the wire
• Against the thread direction of the connection (left thread) � locking of the connection
• Against the stroke direction of the wire � stabilizing of the wire
• Systematic change of the twisting in to avoid out of round wear � constant changing of the position of the beads to each other
Process:
• By wire assembly 1 x per 1 m wire + 6 twists (for number of threads with screw connection) with electroplated wires 1 x 1 per 2 m wire + 6 twists to the left
• Pay special attention to wear of the beads after every cut• Always keep changing the number of twists, + or – 30%
by 10 m wire 10 � 13 � 17 � 22 � 29 � 2 � 17 etc max 3 x per 1 m wire• By the start of large out of the round wear, change the twisting as strongly as possible e.g.
1 � 4 or more per 1 m!
Wear measurement
Measuring of conicity and ovalness of the beads
Measuring points
Bd2
Ad1
B A d1 min
d2
max
d1
max
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Product programme:
Specifications:
Sintered systems:
BS30 reinforced to very heavily reinforced concrete soft to hard aggregates very easy cutting with rubber coating
BS40 reinforced and unreinforced concrete soft to medium hard aggregates high lifetime with rubber coating
BS421 reinforced and unreinforced concrete easy cutting universally applicable with rubber coating
Electroplated systems:
BSG1 reinforced to very heavily reinforced concrete universally applicable soft to very hard aggregates very easy cutting with rubber coating
BSG2 reinforced to very heavily reinforced concrete universally applicable soft to very hard aggregates very easy cutting with plastic coating
BSG3 reinforced to very heavily reinforced concrete universally applicable soft to extremely hard aggregates extremely easy cutting highest lifetime with plastic coating
ø BS30 BS40 BS421 BSG1 BSG2 BSG3
10 electroplated electroplated electroplated
11 sintered sintered sintered
40 beads per running meter
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Wire saw technology
Accessoires:
Press insert – SEPV 11For manual pressOnly use original TYROLIT inserts!
Assembling device – SMGVFor joint connectionFor pressing in and pressing out of the connection bolt
Pay attention absolutely to the handling advice of the manufacturer!
Hydraulic manual press – SPV 80kN
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Connection system for 5t and 8t manual press:
Screw connection SVS11Standard connection system 20.000 load alternation
Joint connection SVG10Replacement bolts SVGB10For small deflection rollersand drive wheels ≤ 500 mm600.000 load alternation
Repair connection SVR11For repairs with wire breakagesAlso for small deflection rollers and drive wheels 180.000 load alternation
Exact, straight cut
More angular, frayed cut
Cut-off wheel
Cable scissor
Connection assembly:
Without fail cut wire to length with cut-off wheel and not with cable scissors!
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Wire saw technology
Optimum press insert Non-Tyrolit press insert
Optimalpressing
Worsepressing
Influence of the press insert on the pressing:
Causes:• Too low twisting of the wire• Too strong tension on wire• Too little coolant supply• Too short distance between drive wheel and wire entry or exit
Characteristics:• Bead wear
Solution:• Increased twisting in or continuous changing (see application hints)• Reduce feed pressure• Increase coolant supply• Increase distance
One-sided bear wear:
Remedying problems:
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Causes:• Very hard aggregates• Very long contact lengths• Wire speed too high • Concrete very heavily reinforced
Characteristics:• Diamond grain flattened• Diamond grain dogged with iron chips
Solution:• Sharpen in abrasive material, reduce wire speed• Reduce contact lengths, set deflection rollers• Reduce wire speed
Wire not cutting, or very slowly:
Too high wear:
Causes:• Abrasive material• Contact lengths very short• Coolant quantity too low or not optimally applied• Wire speed too low
Characteristics:• Bead wear, larger grain projection• Strong conicity of beads (max. acceptable diameter difference 0,4mm)
Solution:• More wear resistant type• Increase wire speed• Reduce feed pressure• Increase coolant supply and optimize • Increase wire speed
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Wire saw technology
Causes:• Too strong tension on the wire, jamming• Sharp edges• Narrow arc of contact radius• Stronger wire vibrations• Great wear on the connection – wrongly assembled
Solution:• Reduce feed pressure• Break edges• Set deflection rollers• Pay attention to short, free wire lengths• Assemble connection according to instructions
Wire breakage:
Causes:• Wire cut with cable scissors• Wrong pressing• Too strong tension on wire, jamming• Sharp edges• Too narrow arc of contact radius
Characteristics• More angular wire cut• Great wear on the connection
Solution:• Wire cut with cut-off wheel (see connection assembly)• Pressing according to regulations• Reduce feed pressure• Break edges • Set deflection rollers
Connection pull out:
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Causes:• Too strong tension on the wire • Sharp edges• Very different wire diameter• New wire in old, narrow cut• Too long arc of contact
Solution:• Reduce feed pressure• Break edges, deflection rollers• Only use wire with same diameter (max. acceptable diameter-difference 0,2mm)• Cut further with old, somewhat used wire• Additional bore or set deflection rollers
Wire not starting:
• Better distribution of power• Longer arcs of contact• Reduced wire load• With small cross-section
• Shorter arcs of contact• Higher wire load• Good with wide cross-sections
Causes:• Too strong tension on the wire• Too little water, overheating• Slipping of wire on drive wheel, overheating• Sudden jamming
Solution:• Reduce feed pressure• More water, several nozzles• More wire tension• Wedge material
Displacement of the beads: