Application of Metal Ceramic Saw Blades in Curtain Wall Proc

In the field of architectural curtain wall processing, large-size stone (such as granite, marble, and artificial quartz stone with dimensions exceeding 1200mm×2400mm) is widely used due to its aesthetic appeal and structural stability. However, cutting such stone faces unique challenges: the large area increases the risk of material cracking, the high hardness (Mohs hardness 6–8 for granite) accelerates tool wear, and mass production requires both precision and efficiency. Traditional cutting tools like diamond saw blades often struggle with short service life (only 500–800㎡ of cutting area for granite) and high replacement costs, while ordinary metal saw blades lack sufficient hardness to handle hard stones.

Metal ceramic saw blades, combining the high hardness of ceramic phases (e.g., TiC, TiN, with hardness up to HV2800–3200) and the toughness of metal binders (e.g., WC-Co alloy), have emerged as a game-changer for large-size stone cutting in curtain wall processing. This article focuses on two core aspects of their application: adaptation technologies for large-size stone cutting (addressing cracking, precision, and wear issues) and strategies to improve mass production efficiency (optimizing processes and reducing costs), supported by practical engineering cases.

1. Adaptation Technologies of Metal Ceramic Saw Blades for Large-Size Stone Cutting in Curtain Wall Processing

Large-size stone in curtain wall projects has strict requirements for cutting quality—perpendicularity tolerance ≤0.5mm/m, edge chipping ≤1mm, and no internal cracks. To meet these standards, metal ceramic saw blades require targeted adaptations in tooth design, matrix structure, and cutting parameter matching.

1.1 Tooth Design: Balancing Cutting Sharpness and Anti-Chipping Performance

The tooth is the core cutting component of the saw blade, and its design directly affects cutting efficiency and stone edge quality. For large-size stone (especially brittle materials like marble and thin granite slabs), the following tooth adaptations are critical:

Tooth Profile Optimization: Adopt a "double-bevel tooth" (primary bevel angle 15°–20°, secondary bevel angle 30°–35°) instead of a traditional flat tooth. The primary bevel (narrow edge) quickly penetrates the stone surface to reduce cutting resistance, while the secondary bevel (wide edge) supports the cut edge to prevent chipping. For example, when cutting 20mm-thick marble slabs (size 1800mm×3600mm), using double-bevel teeth reduces edge chipping from 3mm (flat teeth) to ≤0.8mm.

Tooth Spacing Adjustment: Increase tooth spacing from 8–10mm (standard) to 12–15mm for large-size stones. Larger spacing improves chip evacuation—during high-speed cutting, stone chips (especially granite dust) are quickly discharged, avoiding chip accumulation that causes tooth clogging and overheating (which can lead to ceramic phase detachment).

Tooth Tip Material Matching: For different stone types, select metal ceramic composites with varying ceramic phase contents:

Granite (high hardness, low brittleness): Use TiC-based metal ceramics with 60%–70% ceramic phase content—high hardness resists wear, ensuring a cutting life of 1200–1500㎡ (2–3 times that of diamond saw blades).

Marble (low hardness, high brittleness): Use TiN-based metal ceramics with 50%–60% ceramic phase content—higher toughness prevents tooth tip chipping when cutting brittle marble, reducing tool replacement frequency by 40%.

1.2 Matrix Structure: Enhancing Stability to Avoid Large-Size Stone Deformation

The matrix (the metal base of the saw blade) bears the cutting force and maintains the saw blade’s flatness. For large-size stone cutting, the matrix must resist bending and vibration to prevent uneven cutting (e.g., "wavy edges" on stone slabs). Key adaptations include:

High-Strength Matrix Material: Adopt 65Mn steel or 42CrMo alloy instead of ordinary Q235 steel. These materials have a tensile strength of ≥900MPa and yield strength of ≥750MPa, ensuring the matrix does not deform under high cutting torque (up to 500N·m for 1600mm-diameter saw blades).

Reinforced Rim Design: Add a 3–5mm thick "reinforced rim" (made of WC-Co alloy) around the matrix edge. The rim enhances the connection between the matrix and teeth, reducing tooth detachment caused by vibration—critical for large-size stone cutting, where vibration amplitude is 2–3 times higher than that for small-size stones.

Dynamic Balance Optimization: Perform precision dynamic balancing (G2.5 grade) on the matrix. For saw blades with diameters ≥1200mm, unbalance 量 must be ≤5g・mm/kg. This reduces spindle vibration during high-speed rotation (1800–2200r/min), ensuring the cutting path is straight and perpendicularity tolerance meets curtain wall standards.

1.3 Cutting Parameter Matching: Reducing Stress to Prevent Stone Cracking

Large-size stone has a large surface area and thin thickness (often 15–30mm), making it prone to cracking under excessive cutting stress. Metal ceramic saw blades require optimized cutting parameters to balance efficiency and material protection:

Cutting Speed: For granite, use a linear speed of 35–40m/s (corresponding to 1800–2000r/min for 1200mm-diameter saw blades)—high speed reduces the contact time between teeth and stone, minimizing stress accumulation. For marble, reduce speed to 30–35m/s to avoid brittle fracture caused by excessive impact.

Feed Rate: Implement "gradient feed" instead of constant feed. Start with a low feed rate (5–8m/min) for the first 5mm of cutting (to establish a stable cut path), then increase to 10–15m/min (for efficient cutting of the middle section), and reduce back to 5–8m/min when approaching the stone edge (to prevent edge chipping). This strategy reduces large-size stone cracking rate from 8% (constant feed) to ≤1%.

Cooling System: Adopt "high-pressure water mist cooling" (water pressure 1.2–1.5MPa, mist flow 5–8L/min) instead of traditional flood cooling. The fine water mist directly cools the tooth tip (reducing temperature from 600℃ to 150℃) and flushes chips, while avoiding excessive water absorption (which can cause warping in porous stones like travertine).