The correct usage of diamond blades is vital to providing cost effective solutions for the construction industry. The Concrete Sawing and Drilling Association, which happens to be dedicated to the advancement and professionalism of concrete cutting operators, offers operators the tools and skills essential to understand and make use of diamond blades for optimal performance. CSDA accomplishes this goal by providing introductory and advanced training programs for operators with hands-on training in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. Additionally, they offer a number of safety and training videos and also a safety handbook in support of the effort to teach sawing and drilling operators. This post will discuss the usage of diamond tools, primarily saw blades, and give tips for their cost-effective use.
Diamond is well recognized because the hardest substance seen to man. One could believe that an operator of cut to length machine could make use of the hardness characteristics of diamond to maximum advantage, i.e. the harder the more effective. In reality, this is not always true. Whether or not the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear in order to maximize the performance from the cutting tool. This short article will examine the role diamond plays in cutting tools and how an operator may use analytical ways to maximize the usage of the diamond cutting tools thereby increasing productivity and maximizing the lifestyle of your tool.
Diamond crystals may be synthetically grown in numerous qualities, shapes and sizes. Synthetic diamond has replaced natural diamond in practically all construction applications as a result power to tailor-make the diamond for your specific application. Diamond is grown with smooth crystal faces within a cubo-octahedral shape as well as the color is normally from light yellow to medium yellow-green. Diamond is also grown into a specific toughness, which generally increases because the crystal size decreases. The actual size of the diamond crystals, commonly referred to as mesh size, determines the quantity of diamond cutting points exposed on top of a saw blade. On the whole, larger mesh size diamond is commonly used for cutting softer materials while smaller mesh size diamond is utilized for cutting harder materials. However, there are several interrelated things to consider and those general guidelines might not exactly always apply.
The volume of crystals per volume, or diamond concentration, also affects the cutting performance of the diamond tool. Diamond concentration, commonly referred to as CON, is actually a measure of the level of diamond contained in a segment based on volume. A typical reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is typically in the range of 15-50 CON. A 32 CON would mean that the tool has 23 carats per cubic inch, or about 4 carats per segment. Enhancing the diamond concentration through providing more cutting points can certainly make the bond act harder whilst increasing diamond tool life. Optimum performance is possible as soon as the diamond tool manufacturer utilizes his or her experience and analytical capabilities to balance diamond concentration along with other factors to obtain optimum performance for that cutting operator.
Diamond Shape & Size
Diamond shapes can differ from tough blocky cubo-octahedral crystals (Figure 1) to more friable crystals with less well-defined geometry (Figure 2). Diamond crystals with blocky shapes and sharp edges are generally better suited for stone and construction applications. The blocky shape provides greater potential to deal with fracturing, and therefore offers the maximum amount of cutting points and minimum surface contact. This has a direct impact inside a lower horsepower necessity for the transformer core cutting machine and also to increase the life for your tool. Lower grade diamond is less expensive and usually has more irregularly shaped and angular crystals and is also more best for less severe applications.
Synthetic diamond might be grown in many different mesh sizes to match the required application. Mesh sizes are often in the plethora of 20 to 50 U.S. Mesh (840 to 297 microns) in construction applications. The actual size of the diamond crystals, along with the concentration, determines the amount of diamond that can be exposed on top of the cutting surface of the segments in the blade. The exposure, or height, of diamond protrusion (Figure 3) influences the depth of cut of every crystal, and subsequently, the potential material removal rate. Larger diamond crystals and greater diamond protrusion will result in a potentially faster material removal rate if you have enough horsepower available. Typically, when cutting softer materials, larger diamond crystals are utilized, and once cutting harder materials, smaller crystals are utilized.
The diamond mesh size within a cutting tool also directly pertains to the volume of crystals per carat as well as the free cutting ability of the diamond tool. The smaller the mesh size, the greater the diamond crystals, while larger mesh size means smaller diamond. A 30/40 Mesh blocky diamond has about 660 crystals per carat, while a 40/50 Mesh diamond will have 1,700 crystals per carat.
Specifying the appropriate mesh dimension is the work from the diamond tool manufacturer. Producing the right variety of cutting points can increase the life of the tool and minimize the machine power requirements. For example, a diamond tool manufacturer may choose to use a finer mesh size to boost the volume of cutting crystals on the low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is not really a similar, and this is especially true for the strength of diamonds utilized in construction applications. The power of any diamond to withstand an impact load is usually known as diamond impact strength. Other diamond-related factors, including crystal shape, size, inclusions as well as the distribution of these crystal properties, be a factor in the impact strength as well.
Impact strength could be measured and it is commonly referred to as Toughness Index (TI). Moreover, crystals can also be put through extremely high temperatures during manufacturing and quite often during the cutting process. Thermal Toughness Index (TTI) is definitely the way of measuring the power of the diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, letting them return to room temperature, and after that measuring the modification in toughness makes this measurement helpful to a diamond tool manufacturer.
The manufacturer must select the right diamond according to previous experience or input from the operator within the field. This decision is located, partly, about the tool’s design, bond properties, material being cut and Straight core cutting machine. These factors has to be balanced by the selection of diamond grade and concentration that may provide you with the operator with optimum performance with a suitable cost.
In general, an increased impact strength is required to get more demanding, harder-to-cut materials. However, always using higher impact strength diamond that is higher priced will not always help the operator. It might not improve, and can even degrade tool performance.
A diamond saw blade comprises a circular steel disk with segments containing the diamond that are affixed to the outer perimeter from the blade (Figure 4). The diamonds are kept in place with the segment, and that is a specially formulated combination of metal bond powders and diamond, that have been pressed and heated in the sintering press through the manufacturer. The diamond and bond are tailor-designed to the particular cutting application. The exposed diamonds at first glance of the segment do the cutting. A diamond blade cuts inside a manner comparable to how sand paper cuts wood. As the blade cuts, bond tails are formed dexqpky76 trail behind each diamond (Figure 5). This bond tail provides mechanical support for your diamond crystal. Since the blade rotates throughout the material, the diamonds chip away on the material being cut (Figure 6).
The perfect lifetime of a diamond starts in general crystal that becomes exposed with the segment bond matrix. Since the blade starts to cut, a small wear-flat develops and a bond tail develops behind the diamond. Eventually, small microfractures develop, however the diamond remains to be cutting well. Then a diamond starts to macrofracture, and in the end crushes (Figure 7). This is basically the last stage of any diamond before it experiences a popout, where the diamond quite literally pops out of your bond. The blade will continue to function as its cutting action is taken over with the next layer of diamonds which are interspersed throughout the segment.
The metal bond matrix, which can be created from iron, cobalt, nickel, bronze or another metals in a variety of combinations, is designed to wear away after many revolutions from the blade. Its wear rate is designed in order that it will wear for a price that will provide maximum retention from the diamond crystals and protrusion from the matrix in order to cut.
The diamond and bond interact and it is around the manufacturer to deliver the most effective combination dependant on input through the cutting contractor given specific cutting requirements. Critical factors for sides to address are definitely the bond system, material to become cut and machine parameters. A combination of diamond and bond accomplishes several critical functions.