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Stone Block Cutting in Factories

Stone Block Cutting

How Are Stone Block Cutting in Factories?

The raw stone blocks extracted from quarries are known as stone blocks (coupes). These blocks typically have six faces, but in many cases, the surfaces are not perfectly even, and some faces may have fractures. These fractures can cause the block to lose its cubic or rectangular shape. To ensure safety and prevent possible falling or shifting, the blocks must be properly positioned before cutting.

The next step involves placing the stone blocks under specialized cutting machines for precision cutting.

Methods of Cutting Stone Blocks

  1. Cutting Stone Blocks with a Single Blade Saw (Mono-Blade Saw)

A mono-blade saw is often used to even out irregular faces of a stone block before processing. Additionally, it is useful for cutting a single stone slab or block into more manageable pieces.

The mono-blade saw consists of a large cutting blade attached to two movable arms, which help stabilize the blade while cutting. This type of saw is mainly used for correcting irregular shapes before further processing.

  1. Cutting Stone Blocks with Multi-Blade Gangsaws

For high-volume cutting, multi-blade gangsaws are used in well-equipped stone processing factories. At Sakhara & Azhiyaneh, the 64-blade gangsaw is one of the most efficient cutting machines used in stone processing.

Advantages of Multi-Blade Gangsaws

  • Precise and uniform cutting of stone slabs.
  • Adjustable blade spacing for different slab thicknesses.
  • High production volume.

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Blade Spacing and Cutting Process

The spacing between the blades is usually adjustable, and in most cases, the distance is 2.2 cm to produce standard slabs with a thickness of 2 cm.

During the cutting process, the diamond segments on the blade edges gradually grind through the stone, converting approximately 2 mm of the stone surface into powder. This powdered stone is considered cutting waste.

  1. Cutting Stone Blocks with a Bridge Saw (Gantry Saw)

A bridge saw (or gantry saw) is another machine used for cutting stone blocks into smaller sections. It operates faster than a mono-blade saw and is typically used for producing stone strips or slabs.

Each bridge saw is equipped with:

  • A vertically positioned circular saw blade.
  • A horizontally positioned circular saw blade.
  • These blades work simultaneously to cut both the length and width of the slab or stone strip.

Other Stone Block Cutting Machines in Stone Processing

Apart from the primary machines mentioned above, factories also use:

  • Handheld saws for precise manual cutting.
  • Longitudinal saws for cutting stone slabs into strips.
  • Cross-cut saws for sizing stone slabs to desired dimensions.

Advantages and Limitations of Different Cutting Machines

Advantages of Using a Gangsaw

  • High production speed.
  • Capability to cut large stone slabs.
  • Uniform slab thickness.

Limitations of Gangsaws

  • Fixed blade spacing, limiting some customized cuts.

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Advantages of Using a Bridge Saw

  • Efficient cutting of stone blocks into smaller sections.
  • Capable of producing standardized stone slabs in various thicknesses (e.g., 4 cm, 6 cm, 8 cm, 10 cm, etc.).

Limitations of Bridge Saws

  • Maximum cutting width is 62 cm.
  • If a customer requires a slab with a width of 75 cm and a thickness of 8 cm, this cannot be achieved using a bridge saw.

Conclusion

Each Stone Block Cutting method has its own advantages and is chosen based on the required stone dimensions and production needs. Multi-blade gangsaws are the best choice for mass production of standard slabs, while bridge saws and mono-blade saws provide flexibility for customized orders. Understanding the capabilities and limitations of these machines ensures the best results in stone processing.

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