Why does stone sawing produce bending?

The first manifestation of stone sawing bending is the extremely poor flatness of the board in the length direction of the sawing, known as left and right bending. The second manifestation of stone sawing bending is the extremely poor flatness in the direction of sawing depth, known as up and down bending. When the board is bent, reduce the amount of cutting appropriately and increase the horizontal cutting speed; When there is left-right bending, increase the cutting amount appropriately and reduce the horizontal cutting speed, the effect is obvious.

Therefore, in daily production management, it is necessary to strictly implement mature cutting processes. When bending occurs, a thorough and detailed investigation and analysis of the cutting process and execution should be carried out first, and corrective suggestions and preventive measures should be proposed, which can achieve twice the result with half the effort.

It is generally believed that the main reason for the large bending of stone is:

The quality of the saw blade (finished product) used and the circular stone sawing machine, as well as the formulation and execution of the sawing process during customer processing, are directly related. In addition, it is related to the overall operation quality of the saw machine, the installation and maintenance of the saw machine during use, and the cooling and lubrication of the cutting process.

1. Saw blade substrate:

In general, new saw blade substrates undergo tension control flatness and end face runout control before leaving the factory.

The main manifestation is that the processing technology used by the stone processing plant also does not match the tension value of the matrix. When the tension value is too high, it is easy to cause an up-and-down bending phenomenon. Some matrices have reached their service life limit after multiple re-welding, and this phenomenon can also occur. Therefore, when selecting substrates, stone processing plants should not be tempted by cheap prices and choose unqualified substrates. Instead, they should choose high-quality substrates produced by legitimate enterprises.

2. Knife head:

The main reason for the bending of sheet metal during cutting is that the cutting edge is not sharp, and the cutting force is overloaded or the cutting is carried out, resulting in excessive cutting current and bending of the sheet metal. Therefore, before cutting and processing, stone processing plants should adopt cutting-edge measures for new cutting heads. If conditions permit, mechanical cutting can be used to reduce the deviation of radial and end jumps. But in our country, most stone processing plants have simple conditions and cannot use mechanical cutting, but instead use random cutting.

In the process of random cutting, strict cutting and cutting processes should be formulated and executed according to 1/3 or 1/4 of the normal cutting or cutting speed, and the radial runout error of the cutting head should be reduced through sufficient grinding. Otherwise, during the cutting or cutting process under overload, the saw blade substrate cannot withstand a huge load, which will result in deterioration of flatness, tension value, and end face jumping momentum, leading to later cutting bending that the substrate cannot solve.

3. Welding of substrate and blade:

Legitimate blade welding manufacturers generally use high-precision fully automatic welding machines, accompanied by high-precision molds, strict and meticulous welding processes, and quality inspection standards. This can effectively control the impact of blade heating on the flatness, end face runout, radial runout, and tension value of the saw blade substrate during welding, effectively avoiding the chance of saw blade bending during the cutting process.

At the same time, the mix ratio between the blade and the substrate is also an important factor that cannot be ignored. Being too small can easily cause bending of the board when the cutting depth exceeds half of the radius. Therefore, when stone processing enterprises carry out blade welding, they should choose a reputable blade welding production plant with better conditions to ensure the high-quality and efficient cutting of the saw blade products and reduce losses and waste.

4. The operating quality of the entire saw machine:

Based on our years of experience in tracking customer after-sales service and problem-solving, the lateral running guide rail of the saw machine experiences wear and tear after a period of use, resulting in a decrease in accuracy and failure to meet the specified quality control standards. When crawling occurs, the board is prone to bending left and right;

When the longitudinal lifting guide rail of the saw machine is worn out and the accuracy does not meet the specified quality control standards, the board is prone to bending up and down. At the same time, improper adjustment of the gap between the saw guide rails or entry of foreign objects into the guide rails can also lead to bending.

In addition, the poor operation system of the saw machine spindle is also an important factor leading to sheet metal bending. Therefore, the accuracy of the main drive shaft of the saw machine and the reasonable adjustment of the spindle bearing clearance are also very important. Otherwise, irregular sheet metal bending phenomena will occur.

5. Reasons for installation and maintenance of the saw machine during use:

During the use of the saw machine, in addition to normal maintenance and timely removal of foreign objects from the guide rail, when replacing the saw blade, the accuracy requirements for the saw blade flange are particularly strict. Before replacement, it is necessary to strictly check the flatness and end face runout (5-10 threads) of the flange, and remove burrs and foreign objects. If the deviation does not meet the quality control requirements, it must be repaired or replaced. At the same time, the mining car runs smoothly, and the stones are securely placed on the car. It is also crucial to regularly check during the production process and ensure the straightness and absence of foreign objects on the mining car’s guide rails.

6. Cooling and lubrication during the cutting process of the saw machine:

In the process of using a saw machine, to ensure the normal cutting of the saw blade, extend its service life, and improve the quality of the cutting plate, a special stone cutting coolant is generally prepared, and the quality of cooling and lubrication during the production process is stable. The flow rate is sufficient and evenly sprayed onto the saw blade substrate. Some users do not use the prepared coolant, but use tap water for cutting and cooling, Significantly reduced the number of re-welding times and service life of the saw blade substrate, reduced the rate of high-quality saw blade boards, and led to an increase in board costs. Therefore, good cooling and lubrication can effectively improve the service life of saw blades, reduce cutting costs, and prevent the occurrence of board bending.

In the production process, stone processing plants should fully consider the accuracy of the selected saw machine, the quality of the blade, the accuracy of the substrate, and the degree of re-welding when formulating the sawing process. Combined with the difficulty of cutting stone, a reasonable sawing process should be formulated and strictly implemented, and the shortcomings of the saw machine and saw blade should be compensated through reasonable process adjustments.

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