OPTIMIZATION OF OPERATING PARAMETERS OF DIAMOND WIRE SAWING FOR ENHANCING NATURAL STONE EXTRACTION EFFICIENCY
Authors: Syroid Yevhenii , Tolkach Oleksandr , Sydorenko Andrii , Kuznetsov Oleksandr , Bilobrov Dmytrii 
Published: January 2025

Objective. The aim of the study is to improve the efficiency of natural stone cutting processes using diamond wire saw machines in quarries by optimizing operating parameters, particularly current strength. This will help reduce diamond wire wear, enhance cutting productivity, and decrease energy costs, ensuring the stability and economic viability of stone extraction processes.

Methodology. The study was conducted at the Leznykiv Block Quarry using the MKS-55 diamond wire saw machine, whose main parameters include a main drive power of 55 kW, wire speed up to 40 m/s, and a wire length from 20 to 120 m. During the experiments, three levels of current strength were used: 55 A, 60 A, and 65 A, allowing the assessment of this parameter’s impact on cutting efficiency for monoliths of different sizes (6×2 m, 6×3 m, 6×6 m, 6×10 m, 6×12 m, 6×15 m, 6×18 m). Data on wire tension, movement speed, operating duration, and wire temperature were collected and processed using specialized software. The theoretical analysis included mathematical modeling of the effects of operating parameters on the process stability and energy efficiency of cutting.

Results. Experimental studies showed that the highest cutting productivity was achieved at a current strength of 55 A for medium and large cutting areas. Maximum productivity (2.8 m²/h) was observed on an area of 108 m², which is 40% higher compared to smaller areas. This is due to the stability of wire tension and even diamond grain wear under optimal settings. Using a current strength of 65 A provided a higher initial cutting speed (up to 3.14 m²/h for an area of 36 m²) but led to wire overheating and significant productivity decrease after reaching an area of 72 m² (2.09 m²/h). This highlights the importance of temperature control to maintain process stability.

Scientific Novelty. The study systematically analyzed, for the first time, the effects of various current strength levels on the performance of diamond wire machines in processing monoliths of different sizes. Recommendations for optimal cutting parameters were proposed based on the experimental data and theoretical modeling, taking into account the interrelationship between current strength, wire tension, cutting speed, and temperature mode. This enabled the development of approaches to optimize the cutting process, reducing diamond tool wear and enhancing process stability.

Practical Significance. The study’s results can be applied to the setup of diamond wire saw machines at stone extraction enterprises. The most effective mode was found to be with a current strength of 55 A, providing an optimal combination of productivity and wire longevity for medium and large cutting areas. This reduces operating costs, extends equipment life, and lowers energy consumption, which is critical for ensuring the economic efficiency of production processes. Implementing the developed recommendations will improve cutting quality and productivity at stone extraction quarries.

Keywords: diamond wire saw machine, stone cutting, cutting productivity, current strength, process optimization, quarrying, energy efficiency, natural stone extraction.