WIRE SAW TECHNOLOGY

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Wire saw technology

WIRE SAW TECHNOLOGY

The new dimension in flexibility and economic efficiency

Diamond wire saws open up new applicationsNearly unlimited wall thicknesses, the most widely different materials,different cutting guides.Highest flexibility with the positioning of the machine.Ideal with limited amount of space.

The application of TYROLIT wire saws offers the following advantages:• Convincing performances through robust construction and high-

quality raw materials• Under normal conditions, wire breakage can be as good as

excluded• High flexibility and at the same time complete protection through

special rubber- or plastic coating, no corrosion of the carrier wire• High cutting performance, already in new condition, because of

pre-sharpening, time saving right from the start• Optimum water transport through ideal shaping, damage through

overheating (by sufficient water supply) is as good as excluded because of this

• Different specifications, adapted to different materials• System accessories for optimum function• Optimized connection system for the avoiding of wire breakage

Design of the wire saw:

Carrier wire: Fine stranded steel wire with high strength Book load approx. > 19.000 NDiamond ring: Cutting element – like segments with sawsCoating: For fixing the diamond rings on the carrier wire and protection the carrier wire from

corrosionReinforcing spring: For protecting from damage (sliding) and spacers with spring wiresConnection: For connecting the wire ends

Reinforcing spring

Carrier wire Coating Running direction

Connection Diamond ring

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Application hints:

• Pay attention to stable mounting of machine and deflection rollers• Pay attention to the running direction of the wire (arrow) or supporting

wedge of the bond, cone shape of the bead• Twist wire to the left, in order to guarantee an even wear• Avoid wire length under 7 m – too short lengths lead to out of the round

wear of the beads• Round off corners on the workpiece before start of operation, in order to

avoid jamming = Danger of damage• Pay attention to adequate water supply, set optimum water nozzles• Start the wire without load, in order to avoid jamming – if possible with

very reduced wire speed• Wire speed should amount to 16 – 25 m/s, higher wire speed = greater danger of wire breakage• Work with reduced feed pressure by short wire contact lengths – otherwise the high contact pressure

leads to strongly increased wear• Never use wires with a diameter difference of more than 0,2 mm together (the result is jamming in the

cut)• Keep absolutely to safety distances and use protection equipment, in order to avoid an endangering of

persons by a possible wire breakage, see manufacturer’s operating manual• Store wire dry and away from sunlight, in order to avoid corrosion of the carrier wire and brittleness of

the rubber – rusted wire leads to breakages

Sintered diamond impregnated ring = multi layered

Electroplated diamond layer = single layered

Thread

Steel carrier

Carrier: steel body with internal thread for good fixing to carrier wireCutting layer: in sintered or electroplated bonded design

Design of the diamond rings (beads):

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Wire saw technology

Twisting of the wire

• Against the thread direction of the connection (left thread) � locking of the connection

• Against the stroke direction of the wire � stabilizing of the wire

• Systematic change of the twisting in to avoid out of round wear � constant changing of the position of the beads to each other

Process:

• By wire assembly 1 x per 1 m wire + 6 twists (for number of threads with screw connection) with electroplated wires 1 x 1 per 2 m wire + 6 twists to the left

• Pay special attention to wear of the beads after every cut• Always keep changing the number of twists, + or – 30%

by 10 m wire 10 � 13 � 17 � 22 � 29 � 2 � 17 etc max 3 x per 1 m wire• By the start of large out of the round wear, change the twisting as strongly as possible e.g.

1 � 4 or more per 1 m!

Wear measurement

Measuring of conicity and ovalness of the beads

Measuring points

Bd2

Ad1

B A d1 min

d2

max

d1

max

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Product programme:

Specifications:

Sintered systems:

BS30 reinforced to very heavily reinforced concrete soft to hard aggregates very easy cutting with rubber coating

BS40 reinforced and unreinforced concrete soft to medium hard aggregates high lifetime with rubber coating

BS421 reinforced and unreinforced concrete easy cutting universally applicable with rubber coating

Electroplated systems:

BSG1 reinforced to very heavily reinforced concrete universally applicable soft to very hard aggregates very easy cutting with rubber coating

BSG2 reinforced to very heavily reinforced concrete universally applicable soft to very hard aggregates very easy cutting with plastic coating

BSG3 reinforced to very heavily reinforced concrete universally applicable soft to extremely hard aggregates extremely easy cutting highest lifetime with plastic coating

ø BS30 BS40 BS421 BSG1 BSG2 BSG3

10 electroplated electroplated electroplated

11 sintered sintered sintered

40 beads per running meter

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Wire saw technology

Accessoires:

Press insert – SEPV 11For manual pressOnly use original TYROLIT inserts!

Assembling device – SMGVFor joint connectionFor pressing in and pressing out of the connection bolt

Pay attention absolutely to the handling advice of the manufacturer!

Hydraulic manual press – SPV 80kN

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Connection system for 5t and 8t manual press:

Screw connection SVS11Standard connection system 20.000 load alternation

Joint connection SVG10Replacement bolts SVGB10For small deflection rollersand drive wheels ≤ 500 mm600.000 load alternation

Repair connection SVR11For repairs with wire breakagesAlso for small deflection rollers and drive wheels 180.000 load alternation

Exact, straight cut

More angular, frayed cut

Cut-off wheel

Cable scissor

Connection assembly:

Without fail cut wire to length with cut-off wheel and not with cable scissors!

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Wire saw technology

Optimum press insert Non-Tyrolit press insert

Optimalpressing

Worsepressing

Influence of the press insert on the pressing:

Causes:• Too low twisting of the wire• Too strong tension on wire• Too little coolant supply• Too short distance between drive wheel and wire entry or exit

Characteristics:• Bead wear

Solution:• Increased twisting in or continuous changing (see application hints)• Reduce feed pressure• Increase coolant supply• Increase distance

One-sided bear wear:

Remedying problems:

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Causes:• Very hard aggregates• Very long contact lengths• Wire speed too high • Concrete very heavily reinforced

Characteristics:• Diamond grain flattened• Diamond grain dogged with iron chips

Solution:• Sharpen in abrasive material, reduce wire speed• Reduce contact lengths, set deflection rollers• Reduce wire speed

Wire not cutting, or very slowly:

Too high wear:

Causes:• Abrasive material• Contact lengths very short• Coolant quantity too low or not optimally applied• Wire speed too low

Characteristics:• Bead wear, larger grain projection• Strong conicity of beads (max. acceptable diameter difference 0,4mm)

Solution:• More wear resistant type• Increase wire speed• Reduce feed pressure• Increase coolant supply and optimize • Increase wire speed

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Wire saw technology

Causes:• Too strong tension on the wire, jamming• Sharp edges• Narrow arc of contact radius• Stronger wire vibrations• Great wear on the connection – wrongly assembled

Solution:• Reduce feed pressure• Break edges• Set deflection rollers• Pay attention to short, free wire lengths• Assemble connection according to instructions

Wire breakage:

Causes:• Wire cut with cable scissors• Wrong pressing• Too strong tension on wire, jamming• Sharp edges• Too narrow arc of contact radius

Characteristics• More angular wire cut• Great wear on the connection

Solution:• Wire cut with cut-off wheel (see connection assembly)• Pressing according to regulations• Reduce feed pressure• Break edges • Set deflection rollers

Connection pull out:

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Causes:• Too strong tension on the wire • Sharp edges• Very different wire diameter• New wire in old, narrow cut• Too long arc of contact

Solution:• Reduce feed pressure• Break edges, deflection rollers• Only use wire with same diameter (max. acceptable diameter-difference 0,2mm)• Cut further with old, somewhat used wire• Additional bore or set deflection rollers

Wire not starting:

• Better distribution of power• Longer arcs of contact• Reduced wire load• With small cross-section

• Shorter arcs of contact• Higher wire load• Good with wide cross-sections

Causes:• Too strong tension on the wire• Too little water, overheating• Slipping of wire on drive wheel, overheating• Sudden jamming

Solution:• Reduce feed pressure• More water, several nozzles• More wire tension• Wedge material

Displacement of the beads: