Energy Consumption Analysis in Marble Cutting Processing

Hasan Çimen
Technical Education Faculty
Afyon Kocatepe University
Turkey
[email protected]
Said Mahmut Çinar
Technical Education Faculty
Afyon Kocatepe University
Turkey
[email protected]

Abstract: Energy consumption is main cost part in marble cutting processing with
circular sawblades. There exist many parameters that effect the energy consumption. It
is possible to ensure optimization in the consumed energy if effects of such parameters
can be fully understood. In this study, the effects of travel speed and saw rotation
speed on energy consumption for two different natural stones. Cutting tests are realized
with the computer controlled test set. In tests, while travel and saw rotation speeds are
selected in different values, the cutting depth and cooling water is kept fixed. The
results obtained for two cut stones indicate that travel and saw rotation speeds have
significant effects on the consumed energy and the effect of travel speed is greater than
the effect of saw rotation speed.

Introduction
Marble is a material widely used in many fields from past to today with its different natural colors and
patterns. Afyonkarahisaris one the mostimportant marble supplier cities ofthe world and Turkey withits plenty
of marble mines and factories.In Afyonkarahisar,alsothe sectorsthat manufacture marble treating machines and
their spare parts have developed together with the marble industry. Today,if we wholly considerthe industry in
Afyonkarahisar region,the share of marble industry in totalindustry is about 50%. Most of the production costs
in marble treating consist of the consumed electric energy. By using the energy in optimum level,the costs can
be decreased.
Various machines are being used for marble treating at mines and factories. For separating the block marbles
taken from mine to plaques, block cutting machines segmented diamond circular sawblades are used. The name
of such machines kwon as S/T in short originates from Striper and Trimmer words. There exist many parameters
effecting the cutting operation in cutting machines segmented diamond circular sawblades. These parameters are
saw rotation speed, travel speed and direction, cutting depth, mineralogical and physico-mechanic features of
marble, metallurgic and mechanic features of diamond sockets on saw, flowing speed of cooling water and saw
thickness. Many studies have been realized to examine the effects of the said parameters [1-12]. Studies
generally focus on the effects of cutting situation (Buyuksagis 2007, Buyuksagis and Goktan 2005, Xu et al.
2004 and Li and Malkin 2001),cutting parameters(Tutmez et al.2007, Ersoy and Atıcı 2004, Xu et al. 2003 and
Xu et al. 2002) (cutting speed, travel speed, cutting depth) and saw structure on cutting performance and
efficiency (Ersoy et al. 2005,Sun et al. 2002, Chen 2000 and Chen et al. 1999).
Studies made untiltoday generally have focused on saw quality, abrasion and marble physiology. Today,
as decrease in energy consumption is very important,studies on determination of electricenergy consumed in
marble cutting and optimization of consumption are required (Chuang 2005, Kleimaier and Schröder 2004 and
Martynenko and Siregar 2002).In this article,the effects oftravel and saw rotation speeds on energy
consumption is examined. In this paper,the effect of parameters on specific cutting energy isresearched and
improvementsthat can be made are discussed.

402
Test set

Test sets having computer based data acquisition system are being used especially in scientific studiesto
make complex tests easily and transferthe resultsto a computer medium in a secure manner (Hazarika et al.
2006, Zoric and Ilic 2005 and Caldara et al. 1998).In this study, a completely computer controlled test setin
prototype of S/T machine is used (Figure 1). Control oftestsetfrom computerisrealized with an interface
prepared with Delphi program language (Figure 2).

Figure 1. Test set

In thistest set,travel speed, saw rotation speed, cutting depth and flow speed of cooling water can be
adjusted very sensitively on computer. Saw rotation speed,travel speed and flow speed of cooling water can be
changed uninterruptedly in intervals of 4000rpm, 0-4m/min.and 0-20l/min.respectively through there invertors
driving the saw, travel and cooling water pump motors. Besides, vertical and horizontal positioning of saw can
be made in millimeter sensitivity (Çimen et al. 2008).

Figure 2. Interface software

As most ofthe energy in cutting operation is being used from vertical saw part,the energy consumption
measurement and analysis can only be realized for saw motor(Çınar 2007). For measurements, Shark 100
energy analyzeris used. Analyzer, by digitizing the currents and voltages ofthree phase with analog-digital
converter(ADC) with 16 bitresolution and six synchronous system , calculates and transfersthe active,reactive
and apparent power values drawn by the motor, harmonic distortions in current and voltage and consumed
energy values to computer via serialterminal(Çınar 2007).
During the test, data such as current, voltage, power values and saw rotation speed are collected by the
interface program. Data collected by the interface program are recorded in atextfilein orderto be treated in
spreadsheet program later.

403
Tests and Analysis

Cutting operation isrealized with movement of work piece towards to fixed saw. When the movement
directions of saw and work piece given in Figure 3 is considered, down-cutting position isvalid. During the
cutting process, waterisflowed to sawblade in orderto cooling of sawblade and removing of sawdust. All
cutting testsinthis study are realized in the below cutting position.

Bilecik Beige Limestone d = 50 mm Vw = 0,4 m/min.

3,5

P [ kW ] 2,5
2
1432 rpm 1910 rpm 2387 rpm 2864 rpm
1,5

1
0 10 20 30 40 50 60 70 80

t[ s]

Figure 3. Cutting mechanism Figure 4. Cutting test power curve

The data record commences when the work piece touches to the saw and continues untilthe contact of
saw axis with the work piece ceases.In Figure 4, active power graphics obtained from a group oftests made for
different saw rotation speeds are given. As it can be seen, active power demand of motor rises starting from idle
working value and when the saw axis entersinto the work piece completely,itremains almost fixed. The power
demand decreases towards the end oftest and with leaving ofthe saw axis from the work piece,itfalls again to
idle working value. Though the travel speed and saw rotation speed are kept fixed attheiradjusted values,there
may changes in power values.The reason ofthisthe change in hardness of marble during the cutting process as
the marble is not a homogenous material.
The energy accountis made depending on the active power values obtained from the tests. The active
energy is equalto area below the power curve. Total energy used can be determined with the 3.1 integral(Çınar
2007).

T
Etotal = ∫ p(t ) × dt
0 (3.1)

Here, Etotalindicates cutting energy (Ws), p active power function (W) and T cutting time (s).
Mo mentary energy values calculated by multiplying active power values by sampling time are continuously
being added and so total cutting energy is obtained. This energy value is converted from Ws (Watt second) to
k Wh (kilowatt hour) unitin order to be more meaningful.
For specific cutting energy calculation defined as energy consumed per unit volume,the 3.2 formula is
used (Çınar 2007).

w total
SE =
qw (3.2)

Here, SE indicates specific cutting energy (kWh/m3), Etotaltotal cutting energy (kWh) and qw total
volume of channel opened by the saw (m3).In Figure 5, channels opened by the saw on the work piece are seen.

404
 Figure 5. Work piece and cutting channels

qw = ad ⋅ d ⋅ lw
(3.3)
Channel volume (qw) is calculated with the 3.3 formula. Here,lw indicatesthe length of work piece, d
cutting depth and ad channelwidth.

Test results and discussion

In this article,two types of natural stones Bilecik beige marble and Denizlitravertine are used for cutting
tests. The selected two rocks have almost adverse features with respecttotheir physical and mechanical
structures. While Bilecik beige marble has a very hard and small particle dimension, Denizlitravertine has very
soft and big particle dimension.
In the study,total 20 variation tests are made for each rock to observe the effect oftravel speed and saw
rotation speed. Tests are realized for (Vw) 0.3, 0.4, 0.5, 0.6 and 0.7m/min values oftravel speed and (ns) 1432,
1910, 2384 and 2864rpm values of saw rotation speed.
Besides,in all cutting tests,the cutting dept and flow speed of cooling water are fixed in d=50m m value
and in fw=12l/min. value.In Table 1,the specific cutting energy values obtained for each variation are given in
groups. The data summarized inthe Table are discussed below under separate headings.

Bilecik
Denizli beige
Vw ns
travertine marble
[m/ [rp
SE SE
min] m]
[kWh/m3] [kWh/
m3]
1432 464,51 685,37
1910 516,51 713,34
0.3
2384 609,28 800,32
2864 652,12 861,71
1432 390,21 597,48
1910 428,58 615,43
0.4
2384 513,37 668,55
2864 529,19 717,80
1432 340,35 528,88
1910 352,43 534,59
0.5
2384 425,21 585,96
2864 445,14 613,68
1432 339,22 514,59
1910 353,83 549,77
0.6
2384 406,67 570,11
2864 430,31 562,82
405
 1432 327,03 475,27
1910 334,68 478,40
0.7
2384 356,47 505,19
2864 381,22 502,01
Table 1. Specific cutting energy values for variation values

Effect of saw rotation speed on specific cutting energy

With increase of saw rotation speed, specific cutting energy also increases. For each rock examined in the
study, specific cutting energy demonstrates a marked increase especially in low travel speeds (0.3 and 0.4
m/min.)(Figure 6).Increase in saw rotation speed (provided thattravel speed willremain fixed) will cause more
energy consumption unnecessarily as well asit willspeed deformation of sockets. Forthis reason, saw rotation
speed must be keptin a value most convenient forthe cut marble.

1000 700

600
800

500

600
SE 400
SE
[kWh/m3]
[kWh/m3] 300
400
Vw = 0,3m/min. Vw = 0,4m/min. Vw = 0,3m/min. Vw = 0,4m/min.
200
Vw = 0,5m/min. Vw = 0,6m/min. Vw = 0,5m/min. Vw = 0,6m/min.
200
Vw = 0,7m/min. 100
Vw = 0,7m/min.

0 0
1432 1910 2387 2864 1432 1910 2387 2864
Saw rotation speed [rpm] Saw rotation speed [rpm]

(a) (b)
Figure 6. Effect of saw rotation speed on specific cutting energy for Bilecik beige marble (a) and Denizli
travertine (b)

Effect of travel speed on specific cutting energy

According to the analysis made for Bilecik beige marble and Denizlitravertine,increase in travel speed
decreases the specific cutting energy. Whileincrease intravel speed increases the active power demand,itcauses
decrease in cutting time. Decrease in cutting time naturally decreases the specific cutting energy. On the other
hand, for allsaw speeds (1432,1910, 2385 and 2864rpm), values of specific cutting energy come very close to
each other after some definitevalue oftravel speed (Figure 7). The said becoming closer pointin graphics can be
defined as region where the travel speed value getsits optimum value.

1000 700

600
800

500

600
SE 400
SE
[kWh/m3]
[kWh/m3] 300
400

200
ns = 1432rpm ns = 1910rpm ns = 1432rpm ns = 1910rpm
200
ns = 2387rpm ns = 2864rpm
100 ns = 2387rpm ns = 2864rpm

0 0
0,3 0,4 0,5 0,6 0,7 0,3 0,4 0,5 0,6 0,7
Work piece travel speed[m/min.] Work piece travel speed [m/min.]

(a) (b)
Figure 7. Effect oftravel speed on specific cutting energy for Bilecik beige marble (a) and Denizlitravertine (b)

406
 W hen the graphics showing the effect of saw rotation and travel speeds on specific cutting energy are
examined together,itcan be seen thatthe effect oftravel speed on specific cutting energy is greaterthan the saw
rotation speed. Thisis very clear from incline of graphic curves. For thisreason, adjustment oftravel speed
ratherthan speed of saw rotation will be more economical and easy approach.

Results

In this study realized with a completely computer controlled block cutting machine,the effects oftravel
and saw rotation speeds on active energy and specific cutting energy are examined on two natural stones.In this
study,the following results are obtained;
• With increase in travel speed, the specific cutting energy decreases. To increase the travel speed
results with decrease in cutting time and so increase in cutting efficiency.
• To increasethe saw rotation speed results withincrease in specific cutting energy. As increase in saw
rotation speed (provided that travel speed shall be kept fixed) will also increase the active power demand of
motor,this means consuming more energy forthe same work.
• The travel and saw rotation speeds have significant effects on cutting energy. With determination of
optimum values oftravel and saw rotation speeds,itis clearthatthe energy will be ableto be used in productive
manner. Even a saving in rate of 10% in energy consumption will bring significant benefitfor Afyonkarahisar of
which half ofindustry is established on marble treating.
• With studies to be carried out in future on the prototype test set used in that study, travel speed
controllers ensuring optimum energy consumption (like PI, PD, PID and Fuzzy) will be developed. Such
controllers will be able to keep the travel speed in its optimum value by monitoring the energy consumption of
motor during cutting. Besides,in case the expected performance from the developed controllers can be obtained,
it will be also applied on S/T machines used in the industry.

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