This study is an attempt for comprehensive, combining experimental data with advanced analytical techniques and machine learning for a thorough understanding of the factors influencing the wear and cutting performance of multi-blade diamond disc cutters on granite blocks. A series of sawing experiments were performed to evaluate the wear and cutting performance of multi blade diamond disc cutters with varying diameters in the processing of large-sized granite blocks. The multi-layer diamond segments comprising the Iron (Fe) based metal matrix were brazed on the sawing blades. The segment's wear was studied through micrographs and data obtained from the Field Emission Scanning Electron Microscopy (FESEM) and Energy Dispersive X-ray (EDS). Granite rock samples of nine varieties were tested in the laboratory to determine the quantitative rock parameters. The contribution of individual rock parameters and their combined effects on wear and cutting performance of multi blade saw were correlated using statistical machine learning methods. Moreover, predictive models were developed to estimate the wear and cutting rate based on the most significant rock properties. The point load strength index, uniaxial compressive strength, and deformability, Cerchar abrasivity index, and Cerchar hardness index were found to be the significant variables affecting the sawing performance.
Engineering rockmass classifications are an integral part of design, support and excavation procedures of tunnels, mines, and other underground structures. These classifications are directly linked to ground reaction and support requirements. Various classification systems are in practice and are still evolving. As different classifications serve different purposes, it is imperative to establish inter-correlatability between them. The rating systems and engineering judgements influence the assignment of ratings owing to cognition. To understand the existing correlation between different classification systems, the existing correlations were evaluated with the help of data of 34 locations along a 618-m-long railway tunnel in the Garhwal Himalaya of India and new correlations were developed between different rock classifications. The analysis indicates that certain correlations, such as RMR-Q, RMR-RMi, RMi-Q, and RSR-Q, are comparable to the previously established relationships, while others, such as RSR-RMR, RCR-Qn, and GSI-RMR, show weak correlations. These deviations in published correlations may be due to individual parameters of estimation or measurement errors. Further, incompatible classification systems exhibited low correlations. Thus, the study highlights a need to revisit existing correlations, particularly for rockmass conditions that are extremely complex, and the predictability of existing correlations exhibit high variations. In addition to augmenting the existing database, new correlations for metamorphic rocks in the Himalayan region have been developed and presented that can serve as a guide for future rock engineering projects in such formations and aid in developing appropriate excavation and rock support methodologies.