WIRE SAW TECHNOLOGY

WIRE SAW TECHNOLOGY

The new dimension in flexibility and economic efficiency

Diamond wire saws open up new applications

Nearly unlimited wall thicknesses, the most widely different materials,
different cutting guides.
Highest flexibility with the positioning of the machine.
Ideal with limited amount of space.

The application of TYROLIT wire saws offers the following

advantages:
• Convincing performances through robust construction and high-
quality raw materials
• Under normal conditions, wire breakage can be as good as
excluded
• High flexibility and at the same time complete protection through
special rubber- or plastic coating, no corrosion of the carrier wire
• High cutting performance, already in new condition, because of
pre-sharpening, time saving right from the start
• Optimum water transport through ideal shaping, damage through
overheating (by sufficient water supply) is as good as excluded
because of this
• Different specifications, adapted to different materials
• System accessories for optimum function
• Optimized connection system for the avoiding of wire breakage

Design of the wire saw:

Reinforcing spring Connection Diamond ring

Carrier wire Coating Running direction

Carrier wire: Fine stranded steel wire with high strength

Book load approx. > 19.000 N
Diamond ring: Cutting element – like segments with saws
Coating: For fixing the diamond rings on the carrier wire and protection the carrier wire from
corrosion
Reinforcing spring: For protecting from damage (sliding) and spacers with spring wires
Connection: For connecting the wire ends

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Wire saw technology

Design of the diamond rings (beads):

Sintered diamond impregnated Electroplated diamond layer

ring = multi layered = single layered

Steel carrier

Thread

Carrier: steel body with internal thread for good fixing to carrier wire
Cutting layer: in sintered or electroplated bonded design

Application hints:
• Pay attention to stable mounting of machine and deflection rollers
• Pay attention to the running direction of the wire (arrow) or supporting
wedge of the bond, cone shape of the bead
• Twist wire to the left, in order to guarantee an even wear
• Avoid wire length under 7 m – too short lengths lead to out of the round
wear of the beads
• Round off corners on the workpiece before start of operation, in order to
avoid jamming = Danger of damage
• Pay attention to adequate water supply, set optimum water nozzles
• Start the wire without load, in order to avoid jamming – if possible with
very reduced wire speed
• Wire speed should amount to 16 – 25 m/s, higher wire speed = greater danger of wire breakage
• Work with reduced feed pressure by short wire contact lengths – otherwise the high contact pressure
leads to strongly increased wear
• Never use wires with a diameter difference of more than 0,2 mm together (the result is jamming in the
cut)
• Keep absolutely to safety distances and use protection equipment, in order to avoid an endangering of
persons by a possible wire breakage, see manufacturer’s operating manual
• Store wire dry and away from sunlight, in order to avoid corrosion of the carrier wire and brittleness of
the rubber – rusted wire leads to breakages

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 Twisting of the wire

• Against the thread direction of the connection (left thread)

� locking of the connection

• Against the stroke direction of the wire

� stabilizing of the wire

• Systematic change of the twisting in to avoid out of round wear

� constant changing of the position of the beads to each other

Process:

• By wire assembly 1 x per 1 m wire + 6 twists (for number of threads with screw connection) with
electroplated wires 1 x 1 per 2 m wire + 6 twists to the left
• Pay special attention to wear of the beads after every cut
• Always keep changing the number of twists, + or – 30%
by 10 m wire 10 � 13 � 17 � 22 � 29 � 2 � 17 etc max 3 x per 1 m wire
• By the start of large out of the round wear, change the twisting as strongly as possible e.g.
1 � 4 or more per 1 m!

Wear measurement

Measuring of conicity and ovalness of the beads

Measuring points

B A
d2 d1
d2 max
d1 max

B A d1 min

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Wire saw technology

Specifications:
Sintered systems:
BS30 reinforced to very heavily reinforced concrete
soft to hard aggregates
very easy cutting
with rubber coating
BS40 reinforced and unreinforced concrete
soft to medium hard aggregates
high lifetime
with rubber coating
BS421 reinforced and unreinforced concrete
easy cutting
universally applicable
with rubber coating

Electroplated systems:
BSG1 reinforced to very heavily reinforced concrete
universally applicable
soft to very hard aggregates
very easy cutting
with rubber coating
BSG2 reinforced to very heavily reinforced concrete
universally applicable
soft to very hard aggregates
very easy cutting
with plastic coating
BSG3 reinforced to very heavily reinforced concrete
universally applicable
soft to extremely hard aggregates
extremely easy cutting
highest lifetime
with plastic coating

Product programme:

40 beads per running meter

ø BS30 BS40 BS421 BSG1 BSG2 BSG3

10 electroplated electroplated electroplated

11 sintered sintered sintered

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 Accessoires:
Hydraulic manual press – SPV 80kN

Press insert – SEPV 11

For manual press
Only use original TYROLIT inserts!

Assembling device – SMGV

For joint connection
For pressing in and pressing out of the connection bolt

Pay attention absolutely to the handling advice of the manufacturer!

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Wire saw technology

Connection system for 5t and 8t manual press:

Screw connection SVS11

Standard connection system
20.000 load alternation

Joint connection SVG10

Replacement bolts SVGB10
For small deflection rollers
and drive wheels ≤ 500 mm
600.000 load alternation

Repair connection SVR11

For repairs with wire breakages
Also for small deflection rollers
and drive wheels
180.000 load alternation

Connection assembly:

Without fail cut wire to length with cut-off wheel and not with cable scissors!

Exact, straight cut

Cut-off wheel

More angular, frayed cut

Cable scissor

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 Influence of the press insert on the pressing:

Optimum press insert Non-Tyrolit press insert

Optimal Worse
pressing pressing

Remedying problems:

One-sided bear wear:

Causes:
• Too low twisting of the wire
• Too strong tension on wire
• Too little coolant supply
• Too short distance between drive wheel and wire entry or exit

Characteristics:
• Bead wear

Solution:
• Increased twisting in or continuous changing (see application hints)
• Reduce feed pressure
• Increase coolant supply
• Increase distance
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Wire saw technology

Too high wear:

Causes:
• Abrasive material
• Contact lengths very short
• Coolant quantity too low or not optimally applied
• Wire speed too low

Characteristics:
• Bead wear, larger grain projection
• Strong conicity of beads
(max. acceptable diameter difference 0,4mm)

Solution:
• More wear resistant type
• Increase wire speed
• Reduce feed pressure
• Increase coolant supply and optimize
• Increase wire speed

Wire not cutting, or very slowly:

Causes:
• Very hard aggregates
• Very long contact lengths
• Wire speed too high
• Concrete very heavily reinforced

Characteristics:
• Diamond grain flattened
• Diamond grain dogged with iron chips

Solution:
• Sharpen in abrasive material, reduce wire speed
• Reduce contact lengths, set deflection rollers
• Reduce wire speed

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 Wire breakage:

Causes:
• Too strong tension on the wire, jamming
• Sharp edges
• Narrow arc of contact radius
• Stronger wire vibrations
• Great wear on the connection – wrongly assembled

Solution:
• Reduce feed pressure
• Break edges
• Set deflection rollers
• Pay attention to short, free wire lengths
• Assemble connection according to instructions

Connection pull out:

Causes:
• Wire cut with cable scissors
• Wrong pressing
• Too strong tension on wire, jamming
• Sharp edges
• Too narrow arc of contact radius

Characteristics
• More angular wire cut
• Great wear on the connection

Solution:
• Wire cut with cut-off wheel (see connection assembly)
• Pressing according to regulations
• Reduce feed pressure
• Break edges
72 • Set deflection rollers

Wire saw technology

Displacement of the beads:

Causes:
• Too strong tension on the wire
• Too little water, overheating
• Slipping of wire on drive wheel, overheating
• Sudden jamming

Solution:
• Reduce feed pressure
• More water, several nozzles
• More wire tension
• Wedge material

Wire not starting:

Causes:
• Too strong tension on the wire
• Sharp edges
• Very different wire diameter
• New wire in old, narrow cut
• Too long arc of contact

Solution:
• Reduce feed pressure
• Break edges, deflection rollers
• Only use wire with same diameter
(max. acceptable diameter-difference 0,2mm)
• Cut further with old, somewhat used wire
• Additional bore or set deflection rollers

• Better distribution of power

• Longer arcs of contact • Shorter arcs of contact
• Reduced wire load • Higher wire load
• With small cross-section • Good with wide cross-sections

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