Recently, China has emerged as a leader in the mining and processing of stone. Today, China produces 240 different varieties of granite, accounting for 65% of its output [3], 60 varieties of marble and 10 varieties of slate. In 1998, 160 billion square meters of various stone plates were produced for domestic and export markets. There are about 500 companies with the ability to mine and process local stone, and the number of companies is increasing. The rhythm of this number change is also obvious, however, the sharp increase in production has not been reflected in the investment in machine tool technology. Most processing equipment still uses old-fashioned, outdated production methods.
The mining method uses a blasting method, which means that only 5% to 8% of the stone can be used for processing. Many of the selected blocks are often returned from the process because there are many cracks and defects that occur during blasting.
The main use of Chinese granite is as floor tiles and facing tiles.
The Chinese market does not match the use of such products. Because at the world level, these stones are still basically used in well-known buildings, not standard civil buildings. In China, stone competes directly with other civil building materials such as ceramics, cement and wood. To be treated as such, the quality of the finish and dimensional accuracy of the stone used for this purpose is of course lower than the quality requirements of the stone used in the West for well-known construction projects.
The main difference in this regard is the labor market, where labor costs are significantly lower than in Europe; they are also reflected in sawmill investment, automation and overall labor productivity. When mining stones, China used a blasting method that produced irregularly shaped stones that were small enough to be shipped in small trucks and then transported to the processing plant over short distances. Generally, the processing of panels for floor tiles and tiled tiles is generally based on a domestic reciprocating multi-saw system. The system has five combinations of five 1 m diameter and five 1.6 m diameter saw blades. . The productivity of the saw is low because the amount of cutting is limited by the power of the equipment and simple tooling techniques. Typical process parameters for processing ordinary granite are as follows:
Cutting speed around the saw blade: (saw blade with a diameter of 1 m) 27 m/s, (saw blade with a diameter of 1.6 m) 17 m/s
Sawing depth: 1mm
Feeding speed: 5m/min
Sawing efficiency: 50cm2/min or 0.3m2/h per saw blade
Saw machine production efficiency: 24m2 / working day (8 hours per working day)
The stone is then removed from the saw and the sawn stone is manually placed on a spiral-arm polisher and polished with a conventional abrasive. After polishing, these long slabs are cut to the final size on a manual cutter.
Due to the low level of automation and low sawing efficiency used, the requirements for diamond saw blades are not high, so the variety and size of the abrasives seen in this use are different from those commonly used in Europe. Since the sawing efficiency is much slower, the grain size of the abrasive particles is correspondingly finer, and the diamond particle size used in this application is usually 50 to 70 mesh. At this sawing efficiency, the load on the saw blade is low, so the performance of the diamond used is very different from the diamond performance used in similar applications in Europe. The diamond grades required are very irregular, fragile abrasive particles, which enable the saw blade to be sharpened under normal conditions.
The situation in Europe is different for a number of reasons. Europeans have higher living standards than China, so labor costs in Europe are much higher. In order for European major stone producers to be competitive, they must focus on processing, which optimizes productivity and maximizes the yield of raw materials. These methods focus on converting the mined stones into the final product as much as possible while minimizing energy consumption and minimizing unnecessary stone waste. These methods require sawing technology with high speed operation and sophisticated tools that maintain automatic operation for long periods of time. In the 1990s, technology development of machine tools and diamond tools was carried out in Europe, which promoted an increase in production efficiency and a significant reduction in the cost of stone processing.
If we compare the technology used in Europe and the technology in China when producing modular veneers, we can see that there is a big difference between machine tool technology and productivity. In Europe, the production of these tiled tiles is almost fully automated, using efficient machine design and automated handling equipment. The latest equipment for this type of production, 80 pieces of saw blades with a diameter of 1 m can be mounted on a single spindle.
Machine and tool design allows for faster cutting efficiency with typical usage as follows:
Cutting speed around the saw blade: 25 ~ 35m / s
Sawing depth: 1mm
Feeding speed: 17m/min
Cutting efficiency: 170cm2/min per piece or 1.02m2/h
Machine tool production capacity: 640m2 / working day (8 hours per working day)
Under these conditions, the waste must also be miniaturized in order to maximize the output of the product. As a representative example, the width of the saw blade is less than 10mm, while that of China is 12-15mm. Material handling and processing time optimization is also the key to maximizing productivity, so the stone is sawn into sheets and automatically transferred to an automated machine for the second step.
Due to the very high cutting efficiency, the requirements for diamond tools are very high. The grade and particle size of diamond abrasives in this type of application is quite different from that used in China. Due to the high cutting efficiency, the grain size of the diamond abrasive is naturally coarser, and the most common diamond particle size is 30 to 50 mesh. In the case of high cutting efficiency, the load acting on the tool is correspondingly larger, and thus the performance requirements for the diamond are quite different. Typical requirements for diamonds are: good consistency, high strength, and massive particles that allow the tool to maintain a very sharp state with high processing efficiency. At the same time, performance stability can be maintained for a long time under high load use conditions.
The mining method uses a blasting method, which means that only 5% to 8% of the stone can be used for processing. Many of the selected blocks are often returned from the process because there are many cracks and defects that occur during blasting.
The main use of Chinese granite is as floor tiles and facing tiles.
The Chinese market does not match the use of such products. Because at the world level, these stones are still basically used in well-known buildings, not standard civil buildings. In China, stone competes directly with other civil building materials such as ceramics, cement and wood. To be treated as such, the quality of the finish and dimensional accuracy of the stone used for this purpose is of course lower than the quality requirements of the stone used in the West for well-known construction projects.
The main difference in this regard is the labor market, where labor costs are significantly lower than in Europe; they are also reflected in sawmill investment, automation and overall labor productivity. When mining stones, China used a blasting method that produced irregularly shaped stones that were small enough to be shipped in small trucks and then transported to the processing plant over short distances. Generally, the processing of panels for floor tiles and tiled tiles is generally based on a domestic reciprocating multi-saw system. The system has five combinations of five 1 m diameter and five 1.6 m diameter saw blades. . The productivity of the saw is low because the amount of cutting is limited by the power of the equipment and simple tooling techniques. Typical process parameters for processing ordinary granite are as follows:
Cutting speed around the saw blade: (saw blade with a diameter of 1 m) 27 m/s, (saw blade with a diameter of 1.6 m) 17 m/s
Sawing depth: 1mm
Feeding speed: 5m/min
Sawing efficiency: 50cm2/min or 0.3m2/h per saw blade
Saw machine production efficiency: 24m2 / working day (8 hours per working day)
The stone is then removed from the saw and the sawn stone is manually placed on a spiral-arm polisher and polished with a conventional abrasive. After polishing, these long slabs are cut to the final size on a manual cutter.
Due to the low level of automation and low sawing efficiency used, the requirements for diamond saw blades are not high, so the variety and size of the abrasives seen in this use are different from those commonly used in Europe. Since the sawing efficiency is much slower, the grain size of the abrasive particles is correspondingly finer, and the diamond particle size used in this application is usually 50 to 70 mesh. At this sawing efficiency, the load on the saw blade is low, so the performance of the diamond used is very different from the diamond performance used in similar applications in Europe. The diamond grades required are very irregular, fragile abrasive particles, which enable the saw blade to be sharpened under normal conditions.
The situation in Europe is different for a number of reasons. Europeans have higher living standards than China, so labor costs in Europe are much higher. In order for European major stone producers to be competitive, they must focus on processing, which optimizes productivity and maximizes the yield of raw materials. These methods focus on converting the mined stones into the final product as much as possible while minimizing energy consumption and minimizing unnecessary stone waste. These methods require sawing technology with high speed operation and sophisticated tools that maintain automatic operation for long periods of time. In the 1990s, technology development of machine tools and diamond tools was carried out in Europe, which promoted an increase in production efficiency and a significant reduction in the cost of stone processing.
If we compare the technology used in Europe and the technology in China when producing modular veneers, we can see that there is a big difference between machine tool technology and productivity. In Europe, the production of these tiled tiles is almost fully automated, using efficient machine design and automated handling equipment. The latest equipment for this type of production, 80 pieces of saw blades with a diameter of 1 m can be mounted on a single spindle.
Machine and tool design allows for faster cutting efficiency with typical usage as follows:
Cutting speed around the saw blade: 25 ~ 35m / s
Sawing depth: 1mm
Feeding speed: 17m/min
Cutting efficiency: 170cm2/min per piece or 1.02m2/h
Machine tool production capacity: 640m2 / working day (8 hours per working day)
Under these conditions, the waste must also be miniaturized in order to maximize the output of the product. As a representative example, the width of the saw blade is less than 10mm, while that of China is 12-15mm. Material handling and processing time optimization is also the key to maximizing productivity, so the stone is sawn into sheets and automatically transferred to an automated machine for the second step.
Due to the very high cutting efficiency, the requirements for diamond tools are very high. The grade and particle size of diamond abrasives in this type of application is quite different from that used in China. Due to the high cutting efficiency, the grain size of the diamond abrasive is naturally coarser, and the most common diamond particle size is 30 to 50 mesh. In the case of high cutting efficiency, the load acting on the tool is correspondingly larger, and thus the performance requirements for the diamond are quite different. Typical requirements for diamonds are: good consistency, high strength, and massive particles that allow the tool to maintain a very sharp state with high processing efficiency. At the same time, performance stability can be maintained for a long time under high load use conditions.
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