In the past abrasives slurry wire saws were the main method used for cutting these ultra hard and brittle materials. Copper plated piano wires was used to trap abrasive particles (such as alumina or SiC) suspended in mechanical oil or water based coolant. To provide the cutting action and lubrication of the moving wire. The wire diameter used was smaller than 0.15mm and cutting kerf is about 0.19mm and 0.15mm and smaller.

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Abrasive slurry grit ranged from to 250 grit. Viscosity and continuous mixing of the slurry must be maintained in order to produces consistent results. The improvement in diamond wire manufacturing technology and reduction in cost has made diamond wire cutting and industry standard. Diamond wire bonded with diamond offers many advantages in terms of faster cutting speed (frequently triple the speed) and improved surface finish quality (less secondary operations such as polishing). Using Diamond Wire is much cleaner and faster process Today most Diamond Wire is wound around 2, 3,or 4 grooved mandrels in order to allow multiple loops for simultaneous slicing of the same ingot. When the looped wire is running across the ingot, the diamond particles on the surface of the wire will slowly lap/ grind off silicon on micro level (bit by bit). The cutting action is done by reciprocating motion. The wire is used once, and replaced with a new roll.

Typically this type of wire saw can travel at surface speed of 6 mm/sec. The wire moves forward for abut 300mm and this is retraced for abut 200mm. Net advance of the new wire is at an average speed of 2 m/sec with about 100 m new wire passed through each cycle. The wire can run continuously for more than 300 km long. More than 500 slices can be sawn simultaneously. In a production environment 8&#; (200mm) silicon boul can be cut in less than 8 hours and 12&#; (300mm) boul in less than 12 hours.

? Here we explain how to solve the most common problems that can occur when cutting with diamond wire for stone or construction.

WHAT WE OBSERVE
IN THE DIAMOND WIREPOSSIBLE CAUSESOLUTIONBOND DISPLACEMENT
&#; High thread tension
&#; Very little cooling
&#; Wire slides on the pulley matrix due to lack of adhesion
&#; Sudden wire lock&#; Reduce forward speed
&#; Increase cooling
&#; Increase tension
&#; Use wedges to avoid closing of the cutting areaEXCESSIVE CONICITY

&#; Using of a suitable bead
&#; Increase peripheral speed and reduce forward speed
&#; Increase cooling
&#; Increase the profile speed
&#; Switch to a mode of cyclic drilling&#; Abrasive Materials
&#; Small cutting surface
&#; Low / incorrect cooling
&#; Low peripheral speedTHE WIRE DOES NOT START THE CUT
&#; High tension of the wire
&#; Very pronounced corners
&#; Differences in diameter along the wire
&#; High contact arc&#; Reduce forward speed
&#; Round corners
&#; Only use threads with ø with differences not exceeding 0.2mm
.
&#; Use guide pulleysWIRE FLATTENED

&#; Insufficient number of turns per meter
&#; Excessive tension in wire
&#; Low cooling
&#; Insufficient distance between the pulley and the cutting area&#; Increase the number of twist/ turns
&#; Reduce forward speed
&#; Increase cooling
&#; Increase distanceTHE WIRE DOES NOT CUT OR CUTS VERY SLOW

&#; Very hard materials
&#; Very large cutting surface
&#; High peripheral speed
&#; Highly reinforced concrete&#; Reopen with abrasive materials and / or reduce peripheral
speed
&#; Reduce cutting surface using guide pulleys
&#; Reduce peripheral speed
&#; Use appropriate alloyWIRE BREAK
&#; High tension of the wire
&#; Very pronounced corners
&#; Pronounced arc at the entrance of the cut
&#; Strong vibrations at the conection&#; Reduce forward speed
&#; Round corners
&#; Increase cooling
&#; Check balance and wear of the pulleysCONNECTOR AREA LOSE
&#; Incorrect pressing or improper splicing
&#; High tension of the wire
&#; Very pronounced corners
&#; Pronounced arch at the cutting entrance&#; Use the correct press and connector
&#; Reduce forward speed
&#; Round corners
&#; Use guide pulleysDIAMOND IN BEAD
(A) EXPOSED

(B) SATIN
PERIPHERAL SPEED
(A) Increase the speed
(B) Low the speedCOOLING / ADVANCE OF THE MACHINE
(A) Lack of water / Increase speed
(B) Too much water / Reduce speed

We have all encountered problems at some point cutting some material with diamond wire, but with these tips we can take our work to another level. ?

Do you have a question that does not appear in our tips? Can&#;t find the right diamond wire for the job you need to do? Write to us at and we will be happy to advise you. ?

If you are looking for more details, kindly visit Reinforced Concrete Wire Sawing Cutting Diamond Wire.

?Discover our range of diamond wires for stone and construction ?

Diamond Wire for Construction

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Diamond Wire for Construction

Diamond Wire for construction. Bonds of the highest quality, durability, speed and performance. Concrete cutting in all its applications.

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Diamond wire for natural stone

Diamond wire for Natural Stone. Solga Diamant offers more than 20 years of experience manufacturing diamond wires with rubber, plastic and springs.

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?This is how easy it is to work with our diamond wire. ?

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