In the sparks erupted in the construction site, a piece of equipment is 60 revolutions per second speed cutting steel – this is the disc cutting machine in modern production of the typical application of the scene. As a “steel tailor” in the field of industrial manufacturing, this equipment through the high-speed rotation of the cutting disk, metal, stone and other hard materials, precise division, become an indispensable operation equipment for automobile manufacturing, building construction, machining and other industries.
1, the working principle of the disc cutting machine and technological breakthroughs
The core of the disc cutting machine lies in the synergistic operation of its power system and cutting components. Motor-driven spindle driven alloy steel or diamond material cutting blade rotating at high speed, through the line speed of 80-120m / s kinetic energy conversion, to achieve rapid cutting of the workpiece. In recent years, the application of frequency conversion speed control technology has increased the precision of rotational speed control by 40%, which, together with the automatic lubrication system, enables the equipment to maintain a stable output during continuous operation.
Worthy of attention is the breakthrough of ultra-thin cutting blade technology. Through the nano-scale grain strengthening process, the thickness of the latest cutting blade has been compressed to 0.8mm, which not only reduces material loss, but also controls the width of the cutting seam within 1.2mm. This innovation makes the precision instrument processing field began to adopt large-scale disk cutting process, replacing some of the laser cutting equipment.
2、Multi-scenario application of performance advantages
In the metal processing workshop, the disc cutting machine shows the “strong and soft” qualities:
Steel cutting: can handle alloy steel with HRC60 hardness, cutting speed up to 15cm²/min
Aluminum processing: special coated cutting blade realizes burr-free cutting, surface roughness Ra≤3.2μm
Pipe grooving: equipped with angle adjusting device, it can accurately open V-bevel on the surface of Φ50-300mm pipe
When turning to the field of stone processing, the combination of the *diamond cutting blade and the water jet cooling system* solves the problem of traditional cutting. The combination of *diamond cutting blade and water jet cooling system* solves the problem of dust pollution in traditional cutting. A marble processing plant’s measured data show that the use of new disc cutting machine:
Plate yield increased by 28%
Average daily water consumption reduced by 65%
Noise pollution reduced by 12 decibels
3, the golden rule of equipment purchase
In the face of the market from 2,000 yuan to 200,000 yuan ranging from the span of the product, the purchase need to grasp the three core dimensions:
Power matching: small handheld (1.5-3KW) suitable for on-site construction, heavy gantry (15KW +) specializing in batch processing
Cutting blade specifications: diameter 200-500mm corresponding to the different cutting depth, pay attention to the certification mark (such as EN13236)
Safety and protection: mandatory emergency stop device, shield interlocking system, the European Union standard equipment is also required to pass the CE noise certification
some Comparative tests of machinery manufacturing enterprises show that the configuration of variable frequency motor + intelligent braking system models, in the emergency stop can be inertia skidding time from 8 seconds to 1.2 seconds, significantly reducing the operational risk.
4, maintenance of practical skills
To keep the disc cutting machine in peak condition, the need to establish a three-tier maintenance system:
Daily maintenance: clean up debris after each operation, check carbon brush wear (remaining amount <5mm need to be replaced)
Cyclical maintenance: every 200 hours to replace the bearing grease, test the spindle radial runout (standard value ≤ 0.02mm)
Annual overhaul: comprehensive calibration of the transmission system, test insulation resistance (≥ 2MΩ is qualified)
A municipal engineering team of equipment management logs show that the strict implementation of the maintenance protocols of the equipment, the The time between failures was extended from 400 hours to 1,200 hours, and the average annual maintenance cost dropped by 57%.
5, the three major trends in technology iteration
With the advancement of Industry 4.0, the disc cutting machine is experiencing intelligent transformation:
Visual positioning system: CCD camera to identify the cutting path, positioning accuracy of ± 0.1mm
Digital twin technology: simulation of the cutting process in the virtual environment, optimize the combination of parameters
Energy recovery device: the braking energy into electrical energy storage, energy-saving efficiency increased by 18%
In an intelligent manufacturing demonstration base, equipped with AI control system of the disc cutting machine has been realized “a key to change the type” – only a key to change the type – the only thing to do is to change the type. In an intelligent manufacturing demonstration base, the disc cutting machine equipped with AI control system has realized “one-key change” – just scanning the QR code of the material, the equipment can automatically match the best cutting program, compressing the preparation time from 25 minutes to 40 seconds.
From handheld to fully automated, from rough machining to micron-level precision, the evolution of the disc cutting machine is the epitome of the modern industrial pursuit of efficiency and quality. The moment the operator presses the start button, the rotating cutting disk not only cuts through the hard material, but also opens up a new dimension of intelligent manufacturing.
