New Simulation based Method for the Design of Cut-Off Grinding Segments for Circular Saws

Abstract

A new trend in the field of cut-off grinding tools such as circular saws is the application of
deterministic grain pattern, e.g. the ARIX-System. Although the improved performance of
these tools has been proven in a quarry exemplarily, it is not clear how to configure an
optimized grain pattern. It is assumed that the work material, the cutting parameters and the
tool dimensions have an influence on these pattern. In this paper a new method is presented
for the design of cut-off grinding segments for circular saws with defined grain pattern, which
is based on the in-house material removal simulation software CutS. With this simulation, the
influence of variable grain pattern on tool performance and tool life can be tested without the
need for cutting experiments. It is possible to test different material specifications through the
consideration of brittle and ductile material removal mechanisms and adjustable material
removal factors. The influence of macroscopic and microscopic tool wear on the optimized
positioning of grains by means of material removal rate and wear rate is investigated. With
special algorithms, it is also possible to simulate standard tools with stochastically distributed
diamond grains. Computed results will be compared to real cutting experiments of granite
with cut-off grinding segments designed with CutS.