Prediction of specific cutting energy for large diameter circular saws during natural stone cutting

Statistical methods re-utilized for the prediction of specific cutting energy values (SEcut) based on the operational variables of block cutters and rock properties. Performance measurements of seven different types of block cutters were applied to six different carbonate rocks and three stone processing plants. Energy consumption of large diameter circular diamond saw block cutters was measured and recorded for a number of sawblade diameters during the cutting process by means of a portable power analyzer. Additionally, rock samples were collected from stone processing plants for laboratory tests. Uniaxial compressive strength, bending strength, Brazilian tensile strength, point load strength, Shore hardness test, Schmidt hammer hardness test, seismic velocity, water absorption at atmospheric pressure, apparent density, open porosity, sawblade diameter, and depth of cut values were used as input parameters in the analysis for the prediction of SEcut. The reliability of the developed model was tested with statistical methods. The SEcut values for carbonate rocks in the stone cutting process can be predicted successfully for large diameter circular saws in natural stone processing by using the model developed here. ► Energy consumption of block cutters was measured on stone cutting process. ► Industrial SEcut values were calculated for marbles. ► SEcut were analyzed depending on rock characteristics and working parameters. ► SEcut values for carbonate rocks can be predicted successfully from statistical model. ► Prediction model included Schmidt hammer value, depth of cut, and feed rate.