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Experimental and Statistical Evaluation of Cutting Methods in Relation to Specific Energy and Rock Properties

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Abstract

In a processing plant, natural stone can be cut by methods such as circular sawing (CS), frame sawing (FS), water jet cutting (WJC) and abrasive water jet cutting (AWJC). The efficiency of cutting systems can be compared using various parameters. In this study, the specific energy values were determined and compared to evaluate the efficiency of rock-cutting methods. Rock-cutting experiments were performed on 12 different types of rock samples using a circular sawing machine and an AWJC machine. The experimental results showed that the specific energy values in AWJC were generally higher than in CS. In addition, the relationships between specific energy values and rock properties were explained in this study. The Shore hardness and abrasion resistance were found to be strongly related to the specific energy values, and according to these parameters prediction charts of specific energy values were created.

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Abbreviations

ρ w :

Density of water (g/cm3)

μ :

Efficiency coefficient (%)

AR:

Abrasion resistance (cm3/50 cm2)

B :

Brittleness (according to Altindag 2008)

b :

Cutting depth (for circular sawing) (mm)

D :

Density (g/cm3)

d F :

Focus (nozzle) diameter (mm)

E :

Modulus of elasticity (GPa)

E A :

Total energy of abrasive water jet [N m (J)]

E Diss :

Dissipated energy in the workpiece [N m (J)]

E Ex :

Kinetic energy of the jet leaving the workpiece [N m (J)]

F C :

Cutting force (N)

F N :

Normal force (N)

F T :

Tangential force (N)

F X :

Horizontal reactional force in X direction (N)

F Y :

Horizontal reactional force in Y direction (N)

F Z :

Vertical reactional force in Z direction (N)

H :

Diameter of circular saw blade (mm)

h :

Cutting depth (for abrasive water jet) (mm)

H s :

Shore scleroscope hardness

m A :

Abrasive flow rate (g/s)

m W :

Water flow rate (g/s)

P :

Porosity (%)

p :

Pump working pressure (Pa)

Q :

Yield (volume of rock) per unit length of cut (m3/km)

Q V :

Quantity of material sawn (m3)

R 2 :

Coefficient of determination

SE:

Specific energy (MJ/m3)

TS:

Tensile strength (MPa)

UCS:

Uniaxial compressive strength (MPa)

v :

Velocity of jet (m/s)

v t :

Traverse rate of nozzle (mm/s)

v p :

Abrasive particle velocity (m/s)

V P :

Peripheral speed of circular saw blade (m/s)

V T :

Cutting (traverse) speed (m/s)

W :

Power (W)

WA:

Water absorption (%)

α:

The effect (abrasive) angle of normal force (°)

δ:

Angle between cutting force and vertical axis (°)

φ k :

Contact angle of circular sawblade with rock (°)

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Acknowledgments

Some parts of this research were funded by TUBITAK (The Scientific & Technological Research Council of Turkey). The authors are grateful to TOLKA Waterjet and Decoration for their valuable cooperation during the AWJC field work. The authors are very grateful to the editor and the anonymous reviewers for their valuable contribution and constructive attitude.

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Authors and Affiliations

  1. Department of Mining Engineering, Afyon Kocatepe University, Afyonkarahisar, 03200, Turkey

    Irfan Celal Engin

  2. Department of Mining Engineering, Aksaray University, Aksaray, 68100, Turkey

    Fatih Bayram & Nazmi Erhan Yasitli

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  1. Irfan Celal Engin
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  2. Fatih Bayram
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  3. Nazmi Erhan Yasitli
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Correspondence to Fatih Bayram.

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Engin, I.C., Bayram, F. & Yasitli, N.E. Experimental and Statistical Evaluation of Cutting Methods in Relation to Specific Energy and Rock Properties. Rock Mech Rock Eng 46, 755–766 (2013). https://doi.org/10.1007/s00603-012-0284-4

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