Diamond & Related Materials 100 (2019) 107579

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Diamond & Related Materials

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Forces and wear in high-speed machining of granite by circular sawing T

⁎
S. Turchetta , L. Sorrentino
Department of Civil and Mechanical Engineering, University of Cassino and Southern Lazio, 03043 Cassino, Italy

A R T I C LE I N FO A B S T R A C T

Keywords: In stone sawing process, the most adopted tool type is the circular diamond blade, whose duration and per-
Forces formance are influenced by various elements. These factors can be grouped into four categories: the miner-
Wear alogical characteristics of the material to be machined; the working conditions, such as the depth of cut, the feed
Diamond tools rate and the cutting speed; the production process of the diamond segment and the characteristics of both the
Cutting efficiency
matrix and the diamond, such as the size, the type and the concentration of the diamonds and the metal bonding
Speed cutting
formulation hardness. A key factor to increase productivity and reduce processing costs is cutting speed. In fact,
the current trend is to adopt ever higher cutting speeds in order to reduce production times and costs.
The purpose of this work is to evaluate over time the efficiency of the granite cutting process using diamond
discs according to the cutting speed. The analysis was carried out for cutting speeds higher than the parameters
conventionally used in the industrial field which is about 25 m/s. The efficiency of the processing was assessed
by measuring the forces and wear of the tool according to the main process parameters for different working
stages. In particular, the impact of working parameters modifications on the cutting operation of an ornamental
stone was studied by experimental tests carried out on a CNC working centre equipped with a data acquisition
system, suitable for the registration of all the three components of the cutting force.

1. Introduction
Cutting temperature, tool wear and surface integrity depend on
cutting energy and forces. During cutting operation mineral stone ele-
ments are removed from the surface being machined by the movement
of the abrasive grit. Realizing the interactions between the stone and
the abrasive tool is necessary to optimize the machining process of
stone. The causal connection between control parameters and cutting
performances can be simulated by models derived from the analysis of
the events happening during machining operations; a model is neces-
sary to establish the connection between control parameters and the
cutting operation as to predict the wear of the abrasive tool.
In literature there are not many works dealing with cutting opera-
tion of stones. The ideal chipping geometries were studied by Jerro
et al. who introduced a mathematical model; they defined the con-
nection between the thickness and the area of chips by realizing the
ideal chip shape and they studied the connection between chip thick-
ness and the tangential cutting force [1]. Branch et al. investigated the
method to calculate power required for machining operation from the
cutting forces and energies detected by a dynamometer [2], while
Asche et al. carried out a study to define a practical relationship be-
tween tool wear and process parameters [3]. The specific grinding
energy was correlated to chip shape by Pai et al., who observed chip
samples by a scanning microscope [4]. One of the most adopted models
was proposed by Tönshoff et al. and it was suitable for cutting operation
of stone by means of a diamond disk [5]; even if a thorough test
campaign was not carried out to validate it, according to the suggested
model the friction among diamonds, stone, matrix and swarf and the
deformation of both the grits and the material being machined govern
the interactions between workpiece and tool. Another ideal model for
the study of natural stone cutting was introduced by Konstanty and it
was suitable for the analysis of diamond impregnated tools mounted on
both circular and frame saw, even if experimental tests to validate it
were not carried out [6]. A further model, suitable for the definition of
cutting forces under several machining conditions, was proposed by
Turchetta [7–9]. The diamond grit cutting process was simulated by
Wang and Clausen through the study of the single point cutting tool;
they saw that the grooves characters were comparable to the cutting
forces tendency [10]. An analytical model suitable for the prediction of
the maximum wear rates of both matrix and grit was proposed by Di Ilio
et al. who studied the wear mechanism too [11]. Two were the fun-
damental elements at the basis of the tool wear rate indicated by the
model: the grain characteristic and the matrix one, that had to be cal-
culated through experimental tests. The diamond grit wear of a sintered

⁎
Corresponding author.
E-mail address: turchetta@unicas.it (S. Turchetta).

https://doi.org/10.1016/j.diamond.2019.107579
Received 24 June 2019; Received in revised form 9 October 2019; Accepted 12 October 2019
Available online 25 October 2019
0925-9635/ © 2019 Elsevier B.V. All rights reserved.
S. Turchetta and L. Sorrentino
Fig. 1. CNC milling machine and stone machining test.
tool was studied by Carrino et al. [12], while the diamond saw wear
and the material properties were connected to the cutting specific en-
ergy by Ersoy et al. for various stone types [13]. Cu-based diamond
tools were developed and produced through powder metallurgy by
Wang et al. [14], while the configuration of the diamond tool for var-
ious CNC machining processes was studied by Kenda and. Kopač, who
described the forces and the tool wear mechanism operating in different
type of machining technologies [15]. Zhang J. et al. show an innovative
frame saw machine to cut granite. A sawing test and a simulation were
carried out to analyse the sawing trajectory, the surface topography of
the segments and the percentage of worn diamond particles [16].
Turchetta et al. show an innovative prototype machine to cut stone by a
diamond wire. The developed prototype was provided by a sensory
system to measure both the cutting power and the tensile force of the
diamond wire during experimental tests. In this way it was possible to
verify the functionality of the prototype plant and, in the same time, to
evaluate the productivity of the implemented cutting process [17,18].
Wang P. shows the modelling and estimation of production rate in
ornamental stones sawing based on brittleness indexes [19]. Denkena B.
et al. study thin tools for the high speed cutting of granite; in particular
the application of thinner discs is the aim to achieve the standard
market quality while working with lower tool stiffness at higher rota-
tional speeds. Investigations on the influence of the shape, the different
alloys of the steel core and of different bonding systems on process
forces, tool wear and cut quality [20,21]. All these works lack a sys-
tematic study for the evaluation of high-speed machining performance
in cutting granite with diamond disks. Current state of studies points
out how cutting efficiency depends on cutting speed in natural stones
machining.
The current trend in all cutting processes is to work at high cutting
speeds with the aim of reducing processing times and costs. This re-
quires a careful analysis of the performance of the tool that varies with
the cutting speed. In cutting granite with diamond disks, conventional
cutting speeds are around 20–25 m/s. The objective of this paper is to
analyse the performance of the tool in cutting granite at high cutting
speeds, i.e. speeds higher than those conventionally used. In particular,
the machining conditions that are most interesting by an industrial
point of view were investigated. An ornamental stone was machined on
a CNC machining centre, retrofitted with a dynamometer and data
acquisition systems, to investigate the effects of variations in machining
parameters. The sensor data included cutting force measurements fur-
ther divided into measurable components.
2. Sintered diamond tools for natural stone machining
Natural stone machining occurs by using diamond tools for cutting
such as wires, blades disks and for surface machining such as grinders
and mills of different shapes and profiles. Commonly the tool is made of
a super-abrasive grit anchored on a support by means of a bonding.
Support is very important since it transfers the energy between the
2
Diamond & Related Materials 100 (2019) 107579
machine spindle and the abrasive grit, it cushions the forces arising
during the machining process and it gives the desired shape to diamond
tool. Support is generally made up of corrosion resistant Cr-steel. Steel
bodies are heat treated (quench and tempering) to reach approx. 43–45
HRC hardness. Super-abrasive particles have the task of removing the
material: its properties and parameters to be defined are granulometry,
shape and concentration of the bonding. Granulometry expresses the
measurement of the super-abrasive grain size. The shape of the dia-
mond particles may be regular or irregular according to their quality.
Concentration is the quantity, in weight, of the diamond particles for
sector unit volume. Increasing in concentration leads to cost increase
and, therefore, price one. The bonding is an alloy which blocks the
super-abrasive grains to the tool support so that it can carry out cutting,
milling, sharpening, smoothening and profiling economically and in a
technically correct manner. The bonding must guarantee two con-
trasting requisites: cutting capacity and long tool life. At last, the wear
resistance of the bonding must be proper for the abrasive grit type, in
order to warrant the correct protrusion as a function of the character-
istics of the stone to be machined and the process, and it must essen-
tially guarantee the worn grain release in order to assure the grit re-
newal, exposing the unaltered grains that are embedded in the matrix.
The metal powders making up the bonding mixture are iron, copper,
tungsten, cobalt and nickel.
3. Experimental setup
Fig. 1a shows a CNC milling machine chosen to perform the ex-
perimental tests; it is characterized by a 15 kW spindle power, while the
tests have been carried out at a maximum spindle speed of 15,000 rpm.
The material chosen for this study is the Sardinian granite, while the
adopted tool is a sintered diamond disk commonly selected for natural
stone cutting, whose properties are reported in Table 1. As concerns the
process parameters, two values of feed per revolution and four ones of
Table 1
Tool properties.
Tool properties Diamond disk
Diamond mesh [#] 40/50
Diamond concentration [Kts/cm3] 4.4
Tool diameter [mm] 180
Tool thickness [mm] 5
Chemical composition of bonding (%)
Co 42.80
Cu 28.40
C 20.44
O 5.14
Al 2.24
S. Turchetta and L. Sorrentino Diamond & Related Materials 100 (2019) 107579

Table 2 out taking into account the Fy and the Fz components of the cutting
Experimental plan. force. The highest readings obtained for each tool revolution readings
Factors # Levels Levels have been considered from acquired force signals for each test.
For each signal acquired have been calculated the highest values of
Cutting speed “Vc” [m/s] 4 35–45–55–65 components of the cutting force Fy and Fz obtained as average value of
Feed per revolution “f” [mm] 2 0.05–0.10
the peaks measured.
Radial cutting depth “dr” [mm] 1 25
Fig. 3 shows the highest values of Fy and Fz component of the
cutting force as a function of cutting speed for both levels of feed per
Working stage revolution: both components increased with feed per revolution and
they decreased with cutting speed increment. This is due to the fact that
0, 1, 2, 3,4,5 the quantity of material removed by the single abrasive grain decreased
Working stage Working Working Working Working Working
with the increase of the cutting speed, other conditions being equal, so
0 stage 1 stage 2 stage 3 stage 4 stage 5 the components of the cutting force were reduced. Likewise, the chip
section removed by the single abrasive grain increases as the ad-
Material Material Material Material Material Material vancement per revolution increases, with a consequent increase in the
removed removed removed removed removed removed
components of the cutting force. The graph also shows results disper-
0 cm3 600 cm3 1200 cm3 1800 cm3 2400 cm3 3000 cm3
sion very low, which demonstrates repeatability of the test method and
of the tool characteristics.
cutting speed are considered; in addition, 6 stages of working are The graph in Fig. 3 denotes also that the Fy component of cutting
considered. A total of 192 experimental runs are performed, as four force was lower than Fz one that reached maximum values of about
replications are run for each parameter set, as the experimental plan 220 N and about 120 N for a feed per revolution of 0.10 mm and
shows in Table 2. As regards cutting speed, higher values have been 0.05 mm, respectively, while the maximum value of the Fy was about
used compared to the maximum speeds conventionally used in the in- 90 N for a feed per revolution of 0.10 mm. Moreover, in Fig. 3 the re-
dustrial sector for the tested granite, which are around 20–25 m/s, and lations of linear type between the component of the cutting force and
in particular in a range that varies between 35 and 65 m/s. the cutting speed are reported. As can be seen from the graph, the re-
As showed in Fig. 1b, a piezoelectric dynamometer has been em- gression curves obtained show an excellent value of R2.
ployed to evaluate the three components of the cutting force, that are The results show that adopting high cutting speeds allows to in-
Fx, Fy and Fz. The acquisition system is suitable to acquire the signals of crease productivity by reducing process times and to reduce process
the dynamometer for various time intervals and frequencies in order to forces and, consequently, the stresses acting on the workpiece and the
analyse the entire information about the signal of force. It has been diamond grains.
observed that the signal along the three axes is periodic, so the entire
signal information has been collected with 32,768 points. The acqui- 4.2. High-speed cutting of granite: wear analysis
sition system has been completed by an A/D converter and a PC that
sampled the signal at 10 kHz; therefore, each inspection lasted 3.2768 s. The behavior of a diamond tool in respect to wear is the con-
sequence of wear progressions of the single diamonds grain and the
4. Results and discussion bonding constituting the tool (see Fig. 4). This classification and the
related experimental method have been described in previous works
This section shows the forces and wear analysis as a function of [12].
high-speed cutting of granite. At first, the bonding erosion increases the diamond grain protrusion
so as to come into contact with the material being machined (intact
grain). Once in contact, the grain is rounded so as to form a plateau
4.1. High-speed cutting of granite: forces analysis (smoothed grain). Intermittent contact with the workpiece due to tool
rotation leads to cyclical load on the diamond grain which, amplified by
A monitoring strategy has been adopted based on time-domain the inhomogeneity of the stone and the vibrations, causes deterioration
characteristics. Fig. 2 shows typical time domain signals monitored in Y of grain capacity to resist the cut forces and consequently its disin-
(feed) and Z(vertical) directions. Stone cutting has been performed at a tegration after a certain interval of time (fractured grain). The wear
cutting speed of 45 m/s and at a feed per revolution of 0.10 mm. As progression leads finally to a completely fractured particle or to a
figures show, force signals are periodic and regular. Fx component of matrix enough eroded to allow the release of diamond grain (pull-out).
cutting force is negligible compared to Fy and Fz ones since cut takes Other grains will come to the tool cutting surface and the wear cycle
place in the plane. Therefore, cutting forces analysis has been carried starts again. The test conditions are given in Table 2.
A representative sample was extracted from the diamond grain
Fz Fy population scattered on tool surface and its behaviour with regard to
220 wear has been observed. The sample has been selected considering at
200
least 20 grains to be contained on the reference segment surface. The
180
univocal identification of the diamond grain on the reference surface
160
140 has been obtained by LAICA microscope mapping with a magnification
120 of 200×.
F [N]

100 In order to plan the cuts sequence, i.e. to determine the material
80 volume to be removed for each cut, the average life of a diamond grain
60 through preliminary tests has been determined. Each cut removes the
40
same volume of material corresponding to a specific processing con-
20
0 dition defined working stage. The amount of the material removed has
0 5 10 15 20 25 30 35 40 45 50 been set for each working stage and it is equal to 600 cm3. At the end of
time [ms] each working stage, components of cutting force have been measured.
For each force signal, the highest value obtained has been con-
Fig. 2. Time domain signal monitored in Y and Z direction. sidered as the average value of the signal peaks, moreover since the

3
S. Turchetta and L. Sorrentino Diamond & Related Materials 100 (2019) 107579

Fy (f=0.05 [mm]) Fy (f=0.10 [mm]) Fz (f=0.05[mm]) Fz (f=0.10 [mm])

240
220
200
180
160
140
Fy, Fz [N] 120
100
80
60
40
20
0
20 25 30 35 40 45 50 55 60 65 70 75
cung speed [m/s]

f=0.05 mm f=0.10 mm
Fy=69.70-0.6075Vc Fz=160.75-1.065Vc Fy=123.31-1.0275Vc Fz=286-2.27Vc
R2=0.806 R2=0.978 R2=0.9145 R2=0.9527

Fig. 3. Fy and Fz component vs. cutting speed for the two values of f (0.05–0.10 mm); working stage 0.

dispersion obtained after four replications is always limited (< 7%), in
the following graphs have been reported only the average value.
Fig. 5 shows the trend of Fy and Fz component of cutting force as a
function of cutting speed and working stages for a fixed feed per re-
volution of 0.05 mm. In Figure are showed the average force values: Fy
component of cutting force remains almost constant over time for
cutting speed of 35 m/s and 45 m/s, while it increases significantly with
working progression for cutting speed of 55 m/s and 65 m/s. This in-
creasing is particularly evident for cutting speed of 65 m/s. Similar
results have been obtained for Fz component of cutting force. Fig. 6
shows Fy and Fz components trend of cutting force as a function of
cutting speed and as a function of working stages, for a fixed feed per

intact grain smoothed grain

fractured grain pull-out grain

Fig. 4. Wear states of a diamond grain.

4
S. Turchetta and L. Sorrentino Diamond & Related Materials 100 (2019) 107579

240
Fy (working stage 1)
220
Fy (working stage 2)
200
180 Fy (working stage 3)

160 Fy (working stage 4)

Fy,Fz [N] 140 Fy (working stage 5)
120 Fz (working stage 1)
100 Fz (working stage 2)
80
Fz (working stage 3)
60
Fz (working stage 4)
40
Fz (working stage 5)
20
30 35 40 45 50 55 60 65 70
cung speed [m/s]

Fig. 5. Fy and Fz component vs. cutting speed for different working stages; f = 0.05 mm.

360
340 Fy (working stage 1)
320
Fy (working stage 2)
300
280 Fy (working stage 3)
260
240 Fy (working stage 4)
220 Fy (working stage 5)
Fy,Fz [N]

200
180 Fz (working stage 1)
160
Fz (working stage 2)
140
120 Fz (working stage 3)
100
80 Fz (working stage 4)
60 Fz (working stage 5)
40
30 35 40 45 50 55 60 65 70
cung speed [m/s]

Fig. 6. Fy and Fz component vs. cutting speed for different working stages; f = 0.10 mm.

60%
55% intact grain-f=0.05

50% smoothed grain-f=0.05

percentage of diamond grains

45%
40% fractured grain-f=0.05
35% pull-out grain-f=0.05
30%
25% intact grain-f=0.10
20%
smoothed grain-f=0.10
15%
10% fractured grain-f=0.10
5%
pull-out grain-f=0.10
0%
0 1 2 3 4 5
working stage

Fig. 7. Percentage of diamond grains morphology for different working stage; Vc = 35 [m/s] and f = 0.05; 0.10 [mm].

5
S. Turchetta and L. Sorrentino Diamond & Related Materials 100 (2019) 107579

60%
55% intact grain-f=0.05

50% smoothed grain-f=0.05

percentage of diamond grains

45%
40% fractured grain-f=0.05
35% pull-out grain-f=0.05
30%
25% intact grain-f=0.10
20%
smoothed grain-f=0.10
15%
10% fractured grain-f=0.10
5%
pull-out grain-f=0.10
0%
0 1 2 3 4 5
working stage

Fig. 8. Percentage of diamond grains morphology for different working stage; Vc = 45 [m/s] and f = 0.05; 0.10 [mm].

60%
55% intact grain-f=0.05

50% smoothed grain-f=0.05

percentage of diamond grains

45%
40% fractured grain-f=0.05
35% pull-out grain-f=0.05
30%
25% intact grain-f=0.10
20%
smoothed grain-f=0.10
15%
10% fractured grain-f=0.10
5%
pull-out grain-f=0.10
0%
0 1 2 3 4 5
working stage

Fig. 9. Percentage of diamond grains morphology for different working stage; Vc = 55 [m/s] and f = 0.05; 0.10 [mm].

60%
55% intact grain-f=0.05

50% smoothed grain-f=0.05

percentage of diamond grains

45%
40% fractured grain-f=0.05
35% pull-out grain-f=0.05
30%
25% intact grain-f=0.10
20%
smoothed grain-f=0.10
15%
10% fractured grain-f=0.10
5%
pull-out grain-f=0.10
0%
0 1 2 3 4 5
working stage

Fig. 10. Percentage of diamond grains morphology for different working stage for Vc = 65 [m/s] and f = 0.05; 0.10 [mm].

revolution of 0.10 mm; the components of cutting force is almost con- occurs; its increase is probably due to a greater wear of the diamond
stant with the working progress for cutting speed of 35 m/s, 45 m/s and grains.
55 m/s. By reaching the cutting speed of 65 m/s a considerable increase In order to better understand this phenomenon, for each working
of Fy and Fz component of the cutting force with the working progress stage have been monitored the characteristics of a single diamond grain

6
S. Turchetta and L. Sorrentino
Fig. 11. Performance index as a function of the cutting speed; f = 0.05 [mm].
Fig. 12. Performance index as a function of the cutting speed; f = 0.10 [mm].
belonging to a two-sector taken as a reference on the disc for minimum
40 grains. In particular, the diamonds were classified according to the
different working stages (intact grain, smoothed grain, fractured grain,
pull-out grain, as visible in Fig. 4) characterized using a procedure re-
ported in (test protocol for micro-geometric wear of sintered diamond
tools [12]).
Figs. 7–10 show the percentage values of diamonds morphology for
different working stage: for all tests a low dispersion was found (< 5%).
In Fig. 7 (cutting speed of 35 mm/s), for f = 0.05 mm, the percen-
tage of intact grains is about 42%, the percentage of smoothed grains is
about 13%, the percentage of fractured grains is about 32% and finally
the percentage of pull-out grains is about 13%; for f = 0.10 mm, the
percentage of intact grains is about 47%, the percentage of smoothed
grains is about 12%, the percentage of fractured grains is about 27%
and finally the percentage of pull-out grains is about 14%. This high
percentage of intact and fractured grains, combined with a low per-
centage of the smoothed ones, indicates a good cutting behaviour of the
tool; during the working progress a constant and optimal renewal of
diamond grits occurs. Similar results have been obtained with a cutting
speed of 45 mm/s, see Fig. 8.
Figs. 9–10 show the percentage values of diamonds morphology for
different working stage and cutting speed of 55/65 m/s. It is noticed a
considerable increase of the percentage of smoothed grain (> 30%),
tending to increase with the working stages; the percentage of intact
grains is < 35% and it tends to decrease with the working stages. It is
clear that working with a cutting speed of 55 and 65 m/s is not possible
to obtain a good renewal of diamond grits, so it is possible to increase
the cutting speed up to 45 m/s. This low renewal of diamond grits for
high cutting speed are essentially due to the maximum chip section
7
Diamond & Related Materials 100 (2019) 107579
removed by a single diamond during the cutting process combined with
the low process forces in working stage 0 exerted on the diamond and
on the matrix. Figs. 11 and 12 show the performance index obtained as
the ratio between the number of damaged grains (smoothed grains,
fractured grains, pull-out grains) and the intact grains as a function of
the cutting speed, for both level of feed. As it can be seen from Fig. 11,
for a feed of 0.05 mm the smoothed/intact grains performance index
increases drastically with cutting speeds above 45 m/s, going from
about 0.4 to about 1.6, while the pull-out/intact grains performance
index remains almost constant with the cutting speed and the frac-
tured/intact grains performance index presents a fluctuating trend be-
tween 0.4 and 1. For higher feeds, the performance index trends are
similar, even if the values reached are lower.
5. Conclusions
This work points out the relation between the cutting force com-
ponents and the main process parameters (feed per revolution and
cutting speed) for granite cutting by diamond disk. In particular, the
cutting force components increase with feed per revolution and they
decrease with cutting speed raising. The results obtained point out how
it is possible to improve the process efficiency by working with cutting
speed higher than conventional value of about 35 m/s with consider-
able productivity growth. However, the tool wear is compatible for
cutting speed ≤45 m/s as higher values can cause problems due to the
poor renewal of diamond grits, which is important for the effective use
of any sintered diamond tool.
This phenomenon is highlighted by the performance index, that is
obtained as the ratio between the number of smoothed grains and intact
S. Turchetta and L. Sorrentino
grains. This index undergoes a significant increase due to the poor re-
newal of the abrasive grits passing from a cutting speed of 45 m/s to
55 m/s. In conclusion, increasing the cutting speed is possible in natural
stone machining processes using diamond tools in order to increase
productivity; however, there is a limit value beyond which the tool
suffers an evident loss of its cutting capacity.
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