Common Mistakes to Avoid When Using a Wire Saw in Granite Quarry

Kashdra Group offers advanced wire saw for granite quarry with high levels of accuracy, productivity, and reliability in cutting stone. We are known for reliable and high-quality granite quarry services across the globe.

Improper Tensioning of the Wire

• Mistake: If the tension is not correct, it may cause the wire to break or cutting is not effective.
• Solution: Ensure that you check and set the tension from time to time depending on the manufacturer’s recommendations. Over tensioning will lead to the snapping of the wire when under stress while under tensioning will lead to the wire sagging hence reducing the efficiency of the cutting and may also lead to damage to the wire as well as the pulleys. If this is possible, use a tension gauge to properly tension the braid.

Inadequate Cooling and Lubrication

• Mistake: If the wire is not cooled sufficiently, it may overheat and break.
• Solution: Make sure that the cutting area is supplied with enough water or other coolants at all times. Water cools the wire and also acts as a lubricant to the cut thus reducing friction and temperature. Check whether the cooling system is properly working and the water flow is smooth and properly directed towards the cutting area.

Incorrect Wire Selection

• Mistake: Employing the incorrect style or gauge of wire for the granite or cutting application being utilized.
• Solution: Choose the right wire depending on the hardness and abrasiveness of the granite and the nature of the work to be done. Wires are available in various grades and designs (for example, electroplated, sintered) to suit the type of stone and cutting conditions. It is advisable to seek advice from the wire manufacturer or supplier to determine the most suitable wire for the job.

Poor Alignment of the Wire Saw

• Mistake: Irregularity may lead to the uneven wearing of the wire and decrease the cutting performance.
• Solution: Before initiation of the cutting process, ensure that the wire saw is well aligned and while in operation, occasionally check the alignment. It may result in improper cutting of the wire and excessive wear and tear on one side of the wire which may lead to wire failure. It is recommended to use alignment tools and check the alignment regularly to ensure that it is correct.

Neglecting Regular Maintenance

• Mistake: Neglecting to service your vehicle according to the manufacturer’s recommended schedule can cause parts to wear out faster and break down when least expected.
• Solution: Maintain the equipment as required; this includes periodic checks, lubrication and replacement of any damaged components. These include the inspection of the condition of the pulleys, bearings, and wire guides, and the checking of the tensioning and cooling systems. It is important to keep a maintenance log to help identify and schedule such activities.

Ignoring Safety Precautions

• Mistake: Failure to adhere to safety measures may result in cases of accidents and injuries.
• Solution: Ensure you are well protected by wearing the right PPE, make sure that nobody is around the working area, and that you follow all the safety measures. PPE consists of goggles, gloves, helmets, and earplugs. Check that there are safety guards and emergency stop mechanisms and that they are working properly.

Incorrect Feed Rate

• Mistake: Underfeeding or overfeeding the wire saw can lead to low efficiency in cutting and may even harm the machine.
• Solution: To control the feed rate depending on the type of granite and the wire saw, the operator should focus on achieving a smooth and accurate cut. A feed rate that is set too high can result in wire overheating and faster wear while a feed rate that is set too low is ineffective and results in excessive wear on the wire and the pulleys. Observe the cutting process and intervene only when there is a need to change something.