Energy consumption analysis and cutting cost reduction strategies in granite cutting operations

Abstract

The main problem encountered in natural stone cutting has been how to ensure clean and efficient production conditions that minimize saw blade wear and energy consumption, while maximizing production/cutting quantities, involving the finding of a balance between cutting costs and sales price. This study analyzes cutting data from more than 400 cutting cycles in an industrial granite-cutting process, obtained at different feed rates and cutting depths using a two-column block cutter with 23 x 1200 mm saw blades. Of the cutting parameters, feed rate and cutting depth values were varied, and power consumption values were measured using a mobile power analyzer, after which recommendations have been made for efficient cutting. Cutting tests have been conducted under conditions in which the feed rates were 8, 10, 15 and 20 m/min, and the depth of cuts were 3, 4, 6, 8 and 12 mm. The changes in energy consumption values at different depth of cut values and feed rateshave been evaluated under actual production conditions. According to the results of the study, changes in power consumption under shallow and deep cutting conditions were analyzed in detail, and an empirical model is proposed to explain the relationship between power consumption, production speed and saw blade costs.