The bridge type stone cutter is the core equipment for processing quartz
stone slabs, responsible for cutting quartz stone raw materials into specified
specifications of slabs (requiring cutting accuracy ± 0.5mm/m, blade life ≥ 50
㎡/piece), which directly affects the splicing effect and processing cost of the
slabs. If there is a deviation in cutting accuracy (exceeding ± 1mm/m) or rapid
wear of the cutting head (<30 ㎡/piece), it will lead to an increase in scrap
rate and a sharp drop in processing efficiency. Based on the high wear
resistance and easy edge breakage characteristics of quartz stone (Mohs hardness
6-7), a three-step troubleshooting method is summarized to quickly restore
cutting performance.
Step 1: Optimize the cutting system and blade configuration - the core
components determine accuracy and lifespan
Improper material of the cutting head, spindle accuracy, and guide rail
condition are the main causes of cutting deviation and rapid wear.
Poor adaptability of the cutting head or defects in the sintering process:
ordinary diamond cutting heads are used, but the hardness of the matrix is
insufficient (HRC<35), which cannot cope with the high hardness of quartz
stone; If the diamond concentration of the cutting head is less than 50%, the
cutting force is insufficient, and it is prone to "slip" wear; Uneven sintering
temperature leads to weak bonding between diamond and matrix, making it easy for
particles to fall off during use. Replace high-grade diamond cutting heads
(concentration 60% -70%, matrix hardness HRC40-45) with quartz stone specific
matrix formula; Check the appearance of the blade head to ensure that there are
no missing particles or cracks. During installation, tighten it with a torque
wrench (torque 35-40N · m) to avoid misalignment.
Spindle vibration or guide rail wear: The radial runout of the spindle
exceeds 0.02mm, and the cutting head swings during cutting, resulting in large
accuracy deviations; The wear of the guide rail exceeds 0.1mm, the slider runs
in a stuck manner, and the cutting trajectory deviates; Insufficient lubrication
exacerbates wear and forms a vicious cycle. Use a dial gauge to detect spindle
runout, replace spindle bearings when out of tolerance, and add high-speed
lubricating grease; Grind and repair the guide rail, apply specialized guide
rail oil, adjust the slider clearance to 0.03-0.05mm, and ensure smooth
operation without jamming.
Step 2: Calibrate operating parameters and cutting mode - parameter matching
improves efficiency and reduces losses
Improper cutting speed, feed rate, and cooling method can exacerbate the
problem.
Unbalanced speed parameters: When the cutting line speed is below 25m/s, the
friction between the cutting head and the quartz stone intensifies, leading to
accelerated wear; Above 40m/s, the impact of the cutting head is too large,
making it prone to edge breakage and decreased accuracy; The feed rate exceeds
5m/min, causing a sudden increase in cutting load and resulting in trajectory
deviation. Adjust parameters through a frequency converter, with a cutting line
speed of 30-35m/s and a feed rate of 3-4m/min; Adopting the "segmented speed
regulation" mode, starting at a low speed (2m/min) in the initial stage,
stabilizing at a constant speed to avoid impact damage.
Insufficient cooling or poor coolant adaptation: When the coolant flow rate
is below 50L/min, it is unable to remove cutting heat in a timely manner,
resulting in high-temperature aging of the cutting head; The coolant
concentration is below 5%, the lubricity is insufficient, and it exacerbates the
friction between the cutting head and the stone; Excessive impurities clog the
nozzle and cause uneven cooling. Select quartz specific coolant (concentration
8% -10%) to ensure a stable flow rate of 60-80L/min; Regularly clean the coolant
filtration system, check the nozzle patency, adjust the nozzle angle to 45 °,
and ensure that the coolant accurately covers the cutting surface.
Step 3: Adapt quartz stone characteristics and tooling protection - avoid
cutting defects at the source
Improper fixation of boards, flatness of raw materials, and grounding of
equipment can affect cutting stability.
The board is not firmly fixed or the waste material is uneven: the vacuum
adsorption force is insufficient (less than 0.06MPa), and the board shifts
during cutting; The flatness deviation of the raw materials exceeds 2mm/m, and
the cutting surface is prone to tilting; Uneven pressure on the fixture leads to
deformation of the sheet metal. Check the sealing of the vacuum system to ensure
that the adsorption force is stable at 0.08-0.1MPa; Before cutting, calibrate
the raw material with a level, level the bottom support points, and ensure that
the flatness deviation is ≤ 0.5mm/m; Adopting multi-point uniform clamping to
avoid excessive local pressure.
Poor grounding of equipment or environmental interference: grounding
resistance exceeding 4 Ω can easily generate static electricity, affecting the
accuracy of electronic control systems; Electromagnetic interference from nearby
high-power equipment causes abnormal operation of servo motors. Standardize
equipment grounding (grounding resistance ≤ 2 Ω) and install static elimination
devices; Install a shielding layer on the control system signal line, keep it
away from electromagnetic interference sources (distance ≥ 5m), and ensure
stable parameter transmission.
Daily maintenance should pay attention to: checking the wear of the cutting
head, the condition of the coolant, and the temperature of the spindle every
day; Calibrate guide rail accuracy, cutting speed, and feed rate weekly; Clean
the spindle air duct and replace the coolant every month; Check the spindle
runout and guide rail wear every quarter, and replace aging seals. By taking the
above measures, the cutting accuracy deviation can be reduced to within ±
0.3mm/m, the service life of the cutting head can be increased to over 65
㎡/piece, and the processing cost can be reduced. If there are still problems, it
is recommended to contact the manufacturer to optimize the compatibility between
the cutting head and equipment, and match the quartz stone processing
requirements.