Experiment no: 8

Aim: Case study of core and plug preparation Introduction:

When a piece of rock or core is wanted to be used for analysis as a sample in the laboratory, several steps, as per-processing steps, should be considered on the sample to be prepared for experiments. The main pre-processing steps are follow: (1)slabbing : the cores need to be slabbed with the aim of making the rock structure visible. this can simply be done by sawning down the middle of the rock and cutting it at desired length. (2) Plugging: one can drill the plug at every one foot of the core. (3) trimming: both end of the plugs and core samples can be trimmed in order to produce high quality thin sliced samples without disturbing the structure of the sample.

Core Slabbing:
Core slabbing is the first step in the preparation of samples for core laboratory experiments. The radial core slabbing saw is a machine for cutting rocks into the smaller parts. . This is basically for cutting a big size outcrop rock into the smaller parts and/or cutting the longer cores to the shorter ones. Radial core slabbing saw is designed for diamond cutting discs only, which is connected to the motor with a shaft and two pulleys and the use of the cooling waters improves the slice quality and cutting speed and reduces the heat which is produced by sawing process. Figure below shows the core slabbing machine. Fig. 1 However, students should consider the following safety notices: 1-This machine must only be operated by qualified personnel specially those who has had the operation training and the safety regulations. 2-Protect yourself from any splash produced by wearing a suitable overall.

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Experiment no: 8

Machine Description:
The machine has a motor which supplies the rotational motion for sawing. The main machine parts are: Radial sawElectro motorShaft, pulleys and rimAdjustable tilting tableCooling system, including pumps, water supply, flexible pipes The rotational motion transmitted by two pulleys from electro motor. At either side, there are three different stepped pulley couples. The speed of motion can be adapted by positioning the compound diamond rim on the suitable stepped pulley couple on the electro motor and saw system. The dimension of rock sample should be smaller than the max height of saw from table to be cut electively. Bigger rocks should be broken to a proper part with other methods. One drawback of this machine is its noise. The machine noise level is around 70 dBa. During the cutting process, the noise level depends on the material to be cut, the type of disc used, the rotation speed and the cooling.

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Experiment no: 8
Experiment operation:
The procedure for cutting a given sample is as follows: If the rock is big then it should first be cut by another method Put the sample on the table Check the tension on the pulleys Adjust the direction of water line on both saw and sample Check water tanks and fill them if they are empty Start the water pump and check the direction of water and check the flow Start the saw by pressing the start bottom Cut the sample by screwing up and down of the saw and pushing the sample table of machine Press the stop button Unclamp the core sample. However, in working with the machine consider the following safety issues: (i) prevent touching of saw with the machine sample table, because of damaging of saw, (ii) protect yourself from any splash and water drops by wearing overall and safety glasses. You should consider the appropriate rotational speed. The motor shaft rotates at 1,440 rpm. When the belt is on the central pulley either on motor side and disc side, the disc rotates at 1,440 rpm. When the belt is on the small pulley on motor side and on the large pulley on the disc side, the disc rotated at 2,160 rpm and finally when the belt is on the large pulley on motor side and on the small pulley on the disc side, the disc rotated at 960 rpm. The schematic diagram of pulleys at both motor side and disc sides are illustrated in Fig. 2.

Figure 2: Motor 1 440 rpm Spindle disc holder

Figure 2: Pulleys Cutting linear speed in meters/seconds versus disc diameter and speed are shown in Table 1.

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Experiment no: 8
Table 1: Cutting speed and disc diameters of core slabbing machine

Disc rpm 960 1440 2160

300 15 22.5 34

350 17.5 26.5 39.5

Disc diameter 400 20 30 45

450 22.5 34 51

500 25 37.5 56.5

For cooling of the saw and sample during the operation, water is used. Water is pumped from water tank and poured directly to the sawing position on the sample. Then, the used water goes to the water tank. Water tank is composed of to different tank. The recycled water first enters to the first tank, and after precipitating of cuttings into this tank, the fresh water overflow to the main water tank.

Maintenance
Keep the machine clean. Do not let water and waste in the tray. Check carefully the v-belt and its strain.

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Experiment no: 8
Plugging using plug drill Press machine
The core cutting machine is designed to cut specimens from cores of between 4 to 6 inches, or from blocks of a similar size. The produced plugs are in two different size of 1 and 1.5 inches. This machinecan be installed on any table (Fig. 3). By screwing down of a hollow plug drill, plugs are cut from the samples. However, students should consider the following safety notices: -The core cutting machine should only be used by qualified operators who have been suitably trained in how to produce the quality of cut required under the prescribed safety conditions.

Machine Description:
The machine can accommodate cores measuring from to 3. A swivel joint with a tap allows Internal irrigation of the core drill and a hose fitted with a tap allows external irrigation of the core drill. The speed can be adjusted by repositioning the belt (1800 rpm 2500 rpm 3500 rpm) like core slabbing machine. The machine comprises of: clamping stand column Spindle-Motor unit adjustable tilting table protective housing clamping unit recycling tank

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Experiment no: 8
Table of machine has a rotating capability up to 45. This capability causes that user can make plugs from any part of slab even deviated sides.

Experiment operation

Check the tension on the pulleys Check the direction of the spindle Fill the recycling tank Screw down the core drill and lock it in place Mount a core sample and lock it firmly in the clamping unit Adjust the lower stop on the core drill. 1-2 mm before the end of slab is sufficient for prevention of plugging the sample in plug driller. . Touching of the driller with table causes severe damage to the driller. Close the core drill protective housing Press the Start button Open the irrigation taps Check the flows Cut the core sample Press the Stop button Unclamp the core sample Speed of rotation can be adjusted by changing pulleys. The procedure for this operation is as: open the pulley cover loosen the 2 locking screws and pulley tension lever pinch together the two sides of the spindle belt change the position of the belt tighten the belts with the lever and lock the two screws in place close the cover If the tension of pulleys is not sufficient then the belt should be changed. The procedure for changing the belt is as follow: make sure that the machine is disconnected open the pulley cover loosen the two clamping screws and the belt tensioning lever pinch together the two sides of the spindle belt change the belts tighten the belts with the lever and lock the two screws close the cover

Maintenance

keep the unit and the protective housings clean remove debris and core particles remove sludge clean all moving parts change the cooling fluid as soon as it is dirty make sure that the machine is disconnected remove the pump and the waste pipe from the recycling tank empty the tanks clean the tanks and the separatorsfill the tank with cooling fluid refit the pump and the waste pipe to the recycling tank 6|Page

Experiment no: 8
Trimming Core Plugs
After preparing plugs in core drill machine, all of them should be cut into desired size. This can be done by trimming machine. Trimming machine is a bench model designed to produce fast, high quality thin sliced samples from all materials without disturbing the structure of the sample (Fig. 4). However, students should consider the following safety notices: Touching any resinous cutting wheel can be dangerous. The machine is fitted with safety devices which prevent the wheel from turning when the hood is open This machine must only be used by a qualified person who has received the proper training required to achieve the quality of cut and the high standard of safety envisaged by the manufacturer.

Figure 4: Trimming core plug machine Machine Description:

The basic model can work either in manual feed or with an optional hydraulic automatic feed which is driven by the domestic water supply (Minimum pressure 1.5 bars). In the automatic mode, user can determine the speed of rotation of saws. The machine consists of two radial saw that can work together and cut both end of pugs simultaneously. Each cuts needs nearly 0.2 litter cooling water. This machine is designed to work with all types of cutting wheel (resinous - diamond - boron carbide) and various accessories and adaptations enable samples or core sections to be cut lengthways. These include cradles or devices for holding the samples configurations using two wheels which allow parallel-sided sections of continuous length to be cut in a single operation. The machine is fitted with a safety cut-out switch which can be reset, or rewound should there be no power, as well as a gradual starting device. When the cover is

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Experiment no: 8
open this safety switch open the electric current and the machine dont work. The use of passivated water is strongly recommended to avoid corrosion.

Experiment operation
The machine can work in both manual and automatic mode. By setting two lever taps on the body of machine, three situations are achieved. The lever taps allow the wheel (saw) to advance or return. quick back mode: in this mode the saws go back quickly and positioned at the start point. This mode can be achieved by setting both taps down. stop manual: in this mode user should handle the position of saws for trimming the plug manually and can be achieved by setting top tap to up and bottom tap to dawn automatic feed: in this situation samples are trimmed automatically by the machine. The rotational speed of the saws can be adjusted by the Movement regulator beside the lever taps.

Manual mode
Steps for operating in manual mode are as follows: Press the start bottom Set the taps to Quick back position, at the end of the race, the lever is independent of jack, Set the taps to the "Manual stop" position. Adjust the direction of water line on saw and sample Check water tanks and fill them if they are empty Start the water pump and check the direction of water and check the flow Close the protective housing of machine By moving the saws to front start trimming of the sample Press the Start button Press the Stop button Unclamp the core sample

Automatic feed (optional)

Steps for operating in automatic feed mode are as follows: Press the start bottom Set the taps to the Automatic feed " position Adjust the direction of water line on saw and sample Check water tanks and fill them if they are empty Start the water pump and check the direction of water and check the flow Close the protective housing of machine Gradually open the movement regulator until the required feed rate is obtained. At the end of the cut, turn the taps to the "Rapid return position. Press the Stop button Unclamp the core sample

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Experiment no: 8
Maintenance:
Apart from keeping the machine properly clean, no specific maintenance is required. Make sure that any sediment or waste matter is removed from the tank before starting. Change the fluid according to the frequency of use and its deterioration over time (shelf life).

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