Diamond wire has been the standard industrial practice in stone excavation for over three decades now. Today new applications in the construction and controlled demolition industry are emerging, which involve the cutting of metals and sometimes diamond wire seems the only viable solution. Diamond tool life cutting metals is about one order of magnitude lower than stone, so a better knowledge of this process is of direct industrial interest. In this paper we report the main results of experimental tests for a cylindrical and a tapered electroplated diamond bead cutting cast iron UNI G250. Experimental data to estimate the optimal process parameters and predict tool life are reported and an experimental model is presented. In addition a new tool wear criterion and a new standardized testing method for diamond bead cutting of cast iron and to compare the performance of different diamond bead ..
