Analysis of specific electricity consumption in disc cutting of granites of various Hardness

The aim of this study is to provide a detailed analysis of specific energy consumption during disc cutting of granites of varying hardness using saw blades of different diameters. The main objective is to identify the patterns of energy consumption depending on the cutting process parameters such as saw blade diameter, feed rate, and cutting depth. This allows for the identification of optimal conditions for reducing energy costs and improving the economic efficiency of granite processing. Methodology. The study is based on experimental measurements of energy consumption during the cutting of granites from three hardness categories: medium (150–180 MPa), high (180–220 MPa), and very high (220–250 MPa). Measurements were conducted using the smart-MAC D103-600 energy analyzer on disc saws with diameters ranging from 1000 to 3500 mm. The research parameters included feed rate, cutting depth, and saw blade diameter. During the experiment, the impact of various factors on energy consumption was assessed, and optimal operating modes for each group of granites were identified. Results. The study showed that increasing the saw blade diameter leads to an increase in specific energy consumption per unit of processed surface area. This increase is due to several factors, including the longer cutting edge, changes in moment of inertia, and increased material resistance. Additionally, significant differences in energy consumption were observed for granites with different hardness. The highest specific energy consumption was recorded when processing very hard granite, while energy consumption was lower for materials of medium hardness. The study determined that optimal conditions for minimizing energy consumption include a cutting depth of 4–6 mm and a speed of 7–8 m/min, while a speed of 6 m/min is less effective due to additional energy losses. Scientific novelty. This research is one of the first to include a comprehensive analysis of the impact of saw blade diameter on energy consumption during the cutting of granites with different hardness. Energy consumption for different saw blade diameters in relation to the physical and mechanical properties of the stone was assessed, which allows for the formulation of new recommendations regarding tool selection and cutting parameters to achieve an optimal balance between energy consumption and process productivity. Practical significance. The results of the study are extremely important for practical application in the stone processing industry. They allow for the optimization of granite cutting processes, particularly by reducing energy consumption, which in turn affects the reduction of operational costs and increases the service life of equipment. The obtained data can be used to select optimal cutting parameters for different types of stone, helping to reduce energy costs and improve production efficiency.