Wear mechanisms of diamond segmenta in cutting of carbon fiber reinforced cement-based composite and optimizing in parameters

Carbon fiber reinforced cement-based composite material (CFRC) is a novel type of composite material that involves the incorporation of carbon fibers into ordinary concrete. This addition effectively enhances the tensile strength, deformation performance, and dynamic load resistance of reinforced concrete structures. Consequently, CFRC has found increasing applications in the construction industry. The objective of this research is to investigate the wear mechanisms of diamond tools during the sawing process of CFRC and offer guidance on cost reduction through the optimization of processing parameters. The wear analysis of diamond segments can be divided into two categories: matrix wear and diamond particle wear. The diamond particles can exist in different states, and the formation of voids resulting from the detachment of diamond particles is considered as a reference point. The analysis reveals that abrasive wear is the main mechanisms of matrix wear in CFRC sawing. The wear resistance is strongly influenced by the proportion of diamond particles in favorable states, which is determined by the applied loads and operating parameters. The proportion of diamond particles exhibits a clear variation with adjustments made to the feeding speed. Notably, an increase in feeding rate results in a significant decrease in the percentage of blunt particles, reducing it from 28% to 6%. To achieve a lower wear rate, a predictive model was established using Design Expert software based on the experimental results. The model demonstrated that a wear rate as low as 268.5 mm/m2 can be achieved with a flywheel speed of 78 r/min and a feeding speed of 90 mm/h. The optimization process, aimed at minimizing wear rate, was successfully carried out without compromising productivity.