Design and Cutting Parameter Optimization of a Diamond Wire Special-Shaped Cutting Robot

The diamond wire saw is an essential cutting tool in the decommissioning process of deep-water jacket platforms. This study addresses the saw-binding phenomenon observed during the flat-cutting of jacket legs by designing a specialized diamond wire cutting robot to optimize kerf geometry. Additionally, to refine underwater cutting parameters, an experiment was conducted on the low-temperature grinding of X65 steel using electroplated diamond beads. The bead surface wear morphology was examined by using scanning electron microscopy. Experimental data were used to analyze the effects of various cutting parameters on material removal rate, bead wear, and grinding ratio. The findings reveal that the wear behavior of diamond grits on the bead surface includes grit integrity, micro-wear, fracture, and pull-off. Based on the grinding ratio data, the recommended cutting parameters are a feed speed of 1.2 mm/min and a cutting speed of 22 m/s. This research provides theoretical guidance for optimizing underwater diamond wire cutting operations.