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Hard and brittle materials are substances characterized by high hardness and low toughness, typically non-conductive or semi-conductive. Examples include stones, glass, silicon crystals, quartz, hard alloys, and ceramics. As science and technology advance, the applications of these materials have expanded significantly, and their processing techniques continue to evolve. Among various processing methods, cutting plays a crucial role, especially in industries such as construction and precision manufacturing. For instance, in the production of decorative stone panels and precision rock components, sawing is often the first step, accounting for over 50% of the total processing cost. Diamond tools are widely used for cutting such materials due to diamond's exceptional hardness and durability, making it an ideal choice for efficient and long-lasting cutting operations.
The primary methods for sawing hard and brittle materials using diamond tools include circular saw blades, diamond band saws, diamond frame saws, and diamond bead saws. Although each technique has its own advantages and application scenarios, they share similar cutting mechanisms and wear patterns. Understanding the sawing mechanism and the wear behavior of diamond tools is essential for optimizing tool design and usage. Researchers around the world have extensively studied the interaction between diamond tools and rocks, focusing on fracture mechanics, wear processes, and cutting forces. These studies have contributed significantly to the theoretical foundation and practical development of diamond-based cutting technologies.
In the early stages of research, scientists like P. Bienert proposed models that described the cutting process of a single diamond grain on rock. His model outlined three key deformation zones: the main cuttings formed due to shear stress, secondary chips generated from plastic deformation under pressure, and larger chips resulting from elastic stress release. Later, M. Meding improved this model by introducing more detailed deformation areas and considering the effects of temperature and pressure during cutting. These models help explain how material is removed during the cutting process and how different factors influence the efficiency and quality of the cut.
Acoustic emission (AE) monitoring has also been employed to assess the condition of the cutting process. Studies show that AE signals correlate with the machinability of rocks, with higher AE values indicating greater difficulty in cutting. This method helps detect micro-fractures and provides insights into the mechanical behavior of the material during sawing. Additionally, scanning electron microscopy (SEM) and polarizing microscopes have been used to observe surface morphology and crack propagation, further enhancing our understanding of the cutting mechanism.
The wear of diamond tools is another critical area of study. Factors such as high pressure, friction, and temperature contribute to the degradation of both the abrasive grains and the matrix. Research has identified several wear mechanisms, including adhesive wear, abrasive wear, diffusion wear, and mechanical fracture. Different types of wear affect the performance and lifespan of the tool, with severe wear potentially leading to reduced cutting efficiency and even tool failure. Understanding these mechanisms allows for better tool design and maintenance strategies.
Sawing force is another important parameter in the cutting process. It determines the power requirements of the machine and the load on the tool, directly influencing cutting performance. Early studies by Tönshoff established relationships between sawing force, grain size, feed rate, and pressure. More recent research has focused on the contributions of rock crush resistance and frictional losses, highlighting the dominant role of friction in energy consumption during cutting.
Overall, while significant progress has been made in understanding the sawing and wear mechanisms of diamond tools, many challenges remain. The complexity of the cutting process, the variability of material properties, and the need for more accurate theoretical models all point to the importance of continued research. Future work should focus on improving the accuracy of predictive models, exploring the micro-scale interactions between the tool and the material, and developing more durable and efficient cutting solutions.