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HOME WORKSHOP
Stone cutting circular saw. home workshop
The principle of operation of a stone-cutting circular saw (KTSP) is very simple (Fig. 1). An abrasive powder, such as silicon carbide, is added to the coolant cell. During rotation, the cutting disc "captures" the abrasive and, at the point of contact with the sawn stone, fixed on the CCP support, scratches a groove, which deepens with each turn, up to the division of the stone into halves. The use of a free abrasive instead of, say, diamond wheels as a working tool has some undeniable advantages. First of all, its cost is an order of magnitude less, and this, as indicated above, is of no small importance. In addition, it is possible to use cutting discs of almost any required size. And this, too, will not require large expenses, since the disks (and they are made of roofing iron) can easily be made independently. But one should also keep in mind one drawback: the performance of sawing with a free abrasive is much lower than with a diamond wheel. Technical data of KCP
Structurally, the KCP consists of two main units: a working unit (Fig. 3) and a power supply located at some distance from the first one (this was done to increase electrical safety during operation). As a drive (Fig. 4), a 12 V DC electric motor from a car radiator fan was used.
The engine housing has undergone a slight revision: two of the three standard fasteners have been removed. The electric motor is placed in a clamp made of galvanized sheet and with the help of a loop at its end and an M6 stud, it is pivotally installed in the brackets on the base. The drive pulley is screwed onto the motor shaft and fixed with a pin with a diameter of 2 mm. The rotation is transmitted to the working spindle by a V-belt (from the generator drive of the Zhiguli car). To tension the belt, the engine housing is connected to the earring through the remaining fastening element. Brass terminals for its connection and control buttons in a special casing are attached to the base next to the engine. The buttons are from an old tube TV (or better, use a regular toggle switch like TV-1-1). The base body (bottom, supports, front, side and rear walls) is made of birch boards 20 mm thick (Fig. 5). The walls are connected in a spike and glued to the bottom. For reliability, the elements are additionally fastened with screws. After assembly, the body is impregnated with heated drying oil and painted with oil paint. Further, a 5-liter plastic bottle from drinking water is inserted into the base, a recess is cut out in place under its neck in the front wall. Then the bottle is cut lengthwise at the height of the walls of the base. The resulting cuvette along the perimeter is nailed to the walls of the base with small nails. Under the neck of the cuvette, a chute made of galvanized sheet 0,8 mm thick is attached to the front wall, and lid clamps are installed on top. The upper ends of the side walls are covered with reflective strips 30 mm wide cut from plastic bottles. The strips are fixed with an overlap inside the base with small nails. They serve to protect the gaps and joints between the walls of the base and the cuvette from the ingress of coolant with abrasive during the operation of the CCP. In addition to these parts, an earring for mounting the engine when the belt is tensioned, a central reflector and caliper supports are mounted on the base.
After that, we proceed to the assembly and installation of the working spindle (Fig. 8). First of all, we determine the position of the shaft. To do this, we fix the engine on the earring, as shown in Figure 3, put on the belt on the driving and driven pulleys and tighten it, shifting the driven pulley towards the back wall of the base. Having fixed the pulley, through the hole in its hub we mark the center of the hole for the spindle shaft on the side wall of the base. We transfer the marking to the opposite wall and drill holes in the side walls with a diameter of 11 - 12 mm. Then we fix the driven pulley at the end of the shaft, put one plate on the shaft - the bearing, pass it through the right wall of the base, put on two more, pass it through the left wall. We put on the last, fourth plate on the free end of the shaft and fasten all of them in series, providing a light tension on the drive belt and free rotation of the shaft. Next, we take the shaft out of the base, fill the holes in the side walls with CIATIM-201 type grease and, returning the shaft to its place, successively string washers, a bushing with a cutting disc fixed on it and a spring onto it. In conclusion, we fix the sleeve on the shaft with a locking screw. The support (Fig. 3,9) is used to fix the stone being cut and to feed it to the cutting wheel. The stone is clamped between a plate and two planks made of 6 mm sheet getinaks. In the plate between the slats, a groove was cut for the exit of the cutting wheel, and a 2 mm hole was drilled at the end, which serves to secure the thread and suspend the load, if necessary, to increase the clamping of the workpiece to the tool. The thread passes through the neck of the cuvette and further along the chute. Installing the caliper is not complicated and is clear from the presented drawings. The main task in this case is to fix the insert with the M5 locking screw so that the cutting wheel is along the axis of the slot. The lid (Fig. 10) consists of a wooden U-shaped frame assembled from birch blocks, a closing bracket made of 3 mm wire and a body (halves of a 5-liter plastic bottle - the remainder of the cuvette). The lid is attached to the base with a small card loop. The work at the KCP is carried out as follows. First, coolant is poured into the base cuvette - a mixture of water and engine oil in a ratio of approximately 15:1.
The amount of coolant must be such that the cutting disc is immersed in it by 8 - 10 mm. Further, abrasive powder in the amount of 30 - 40 g is poured into the cuvette near the cutting disc from the side of the chute. The powder can be obtained from a used silicon carbide grinding wheel (green). After fixing the workpiece on the caliper, it is lowered onto the cutting disc, the KCP cover is closed - and the electric motor is turned on. After 1 - 2 minutes, a characteristic "rustle" should appear, which means that an abrasive is supplied to the cutting wheel and the process of sawing the stone begins. In the first minutes, when the resistance to rotation of the tool is small, a voltage of about 6 - 8 V is set on the power supply by a switch. This allows you to reduce the engine speed and reduce the dropping of the abrasive from the cutting wheel. As the shedding voltage applied to the motor should be gradually increased. As can be seen from figures 3 and 5, the base supports have different heights: the front (at the gutter) - 20 mm, the back - 50 mm. This is done so that the abrasive powder, discharged to the rear wall, "flows" back to the cutting disc. If necessary, the KCP can be rigidly fixed with a clamp on the desktop - for this, the bottom of the base is made 12 mm wider than the side walls. After the end of work, the coolant is drained through the gutter, the abrasive is removed from the cuvette (for further use), the cuvette is washed with warm water and dried. The power supply (the circuit diagram is shown in Fig. 2) has a standard device. A modified TC-180 (from an old tube TV) was used as a transformer. The secondary windings on its coils were replaced with new ones, wound with insulated copper wire with a cross section of 2,5 mm2 (see table). Switch SA1 - type PGK-1-11; signal lamp HL1 - 12 V, 90 mA; capacitor C1 - type BMT-2, C2 - K50-6; switching on toggle switch - type TP1-2. Diodes VD1 - VD4 (D242) are mounted on an aluminum plate 5 mm thick with dimensions 80x100 mm and insulated from it with mica washers. The installation was carried out with a BPVL wire with a cross section of 1,5 mm2. The power supply unit is covered with a casing (made of roofing iron) with dimensions of 190x140x120 mm. In case of difficulties in the manufacture of the power supply unit, the KCP can be powered from any 12 V DC source, for example, from a car battery or a charger for it. Number of turns and voltages in the secondary windings (click to enlarge) Author: L.Stepanov
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