Field and laboratory studies guiding to empirical prediction of cutting and bead consumption rates of diamond wire cutting machines

Predictions of cutting and bead consumption rates of diamond wire cutting machines are major subjects in determining the economics of natural stone quarrying. The main aim of this study is to develop empirical models to predict areal net cutting rate and bead consumption rate of diamond wire cutting machines based on statistical analyses using different physical and mechanical properties of natural stones at macro and micro scales. Firstly, twenty different natural stone quarries in Turkey were visited to collect natural stone samples and record field performance (areal net cutting rate and bead consumption rate) of diamond wire cutting machines. Macro and micro scale tests were applied in the laboratory on twenty-five different natural stone samples of metamorphic and sedimentary origins obtained from the fields. Macro-scale physical and mechanical property tests include density, uniaxial compressive strength, Brazilian tensile strength, Shore scleroscope hardness, and Schmidt hammer hardness. Micro-scale tests include texture coefficient, Knoop microhardness, and mean grain size. Then, simple, multiple linear, and multiple non-linear regression analyses were carried out using the macro and micro scale stone properties and the areal net cutting rate and bead consumption rate. An important feature distinguishing this study from previous ones is the use of micro and macro properties of stones separately and together, as well as the use of a very large number of data with high diversity. Results indicate that the models suggested in this study may be very useful and reliable tools for predicting the areal net cutting rate and bead consumption rate of diamond wire cutting machines.