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

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 wark 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 rernoval 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.