The right use of diamond blades is crucial to providing cost-effective solutions to the construction industry. The Concrete Sawing and Drilling Association, which is dedicated to the advancement and professionalism of concrete cutting operators, offers operators the equipment and skills necessary to understand and utilize diamond blades for optimal performance. CSDA accomplishes this goal by giving introductory and advanced training programs for operators with hands-on education in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. Additionally they offer a series of safety and training videos in addition to a safety handbook in support in their effort to coach sawing and drilling operators. This article will discuss the usage of diamond tools, primarily saw blades, and give tips for their inexpensive use.
Diamond is well recognized since the hardest substance known to man. One would 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 may not be always true. If the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear in order to increase the performance from the cutting tool. This post will examine the role diamond plays in cutting tools and how an operator may use analytical ways to maximize the use of the diamond cutting tools thereby increasing productivity and maximizing the lifespan of the tool.
Diamond crystals may be synthetically grown in a multitude of qualities, shapes and sizes. Synthetic diamond has replaced natural diamond in almost all construction applications for this reason power to tailor-make the diamond to the specific application. Diamond is grown with smooth crystal faces in the cubo-octahedral shape and also the color is normally from light yellow to medium yellow-green. Diamond is also grown to a specific toughness, which generally increases since the crystal size decreases. The dimensions of the diamond crystals, known as mesh size, determines the volume of diamond cutting points exposed on the surface of any saw blade. Generally, larger mesh size diamond can be used for cutting softer materials while smaller mesh size diamond can be used for cutting harder materials. However, there are lots of interrelated factors to consider and those general guidelines might not always apply.
The amount of crystals per volume, or diamond concentration, also affects the cutting performance of the diamond tool. Diamond concentration, known as CON, is really a measure of the amount of diamond incorporated into a segment based on volume. A frequent reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is generally 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. Improving the diamond concentration by providing more cutting points can certainly make the bond act harder while also increasing diamond tool life. Optimum performance may be accomplished as soon as the diamond tool manufacturer utilizes her or his experience and analytical capabilities to balance diamond concentration along with other factors to attain optimum performance for that cutting operator.
Diamond Shape & Size
Diamond shapes may 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 resistance to fracturing, and so offers the maximum quantity of cutting points and minimum surface contact. This has a direct impact in the lower horsepower necessity for the Stack core cutting machine and to maximize the life for the tool. Lower grade diamond is less expensive and usually has more irregularly shaped and angular crystals and it is more best for less severe applications.
Synthetic diamond could be grown in many different mesh sizes to fit the preferred application. Mesh sizes are usually in the range of 20 to 50 United states Mesh (840 to 297 microns) in construction applications. How big the diamond crystals, along with the concentration, determines the quantity of diamond which will be exposed on top of the cutting top of the segments about the blade. The exposure, or height, of diamond protrusion (Figure 3) influences the depth of cut of every crystal, and subsequently, the opportunity material removal rate. Larger diamond crystals and greater diamond protrusion can result in a potentially faster material removal rate if you have enough horsepower available. For the most part, when cutting softer materials, larger diamond crystals are used, and whenever cutting harder materials, smaller crystals are employed.
The diamond mesh size in a cutting tool also directly concerns the volume of crystals per carat and also the free cutting ability of the diamond tool. 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 may have 1,700 crystals per carat.
Specifying the proper mesh dimensions are the position of the diamond tool manufacturer. Producing the proper number of cutting points can maximize the life of the tool and reduce the device power requirements. For example, a diamond tool manufacturer may choose to use a finer mesh size to improve the volume of cutting crystals over a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond will not be the identical, and this is also true for the potency of diamonds employed in construction applications. The capability of any diamond to stand up to a positive change load is normally known as diamond impact strength. Other diamond-related factors, including crystal shape, size, inclusions along with the distribution of those crystal properties, are involved from the impact strength at the same time.
Impact strength may be measured which is known as Toughness Index (TI). Moreover, crystals are also exposed to quite high temperatures during manufacturing and often throughout the cutting process. Thermal Toughness Index (TTI) may be the way of measuring the power of any diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, allowing them to go back to room temperature, then measuring the change in toughness makes this measurement useful to a diamond tool manufacturer.
The company must select the best diamond based on previous experience or input in the operator within the field. This decision is situated, to some extent, around the tool’s design, bond properties, material being cut and Straight core cutting machine. These factors must be balanced by your selection of diamond grade and concentration that can provide you with the operator with optimum performance in a suitable cost.
Generally, an increased impact strength is necessary for additional demanding, harder-to-cut materials. However, always using higher impact strength diamond that is certainly higher priced will never always benefit the operator. It might not improve, and might degrade tool performance.
A diamond saw blade is composed of a circular steel disk with segments containing the diamond that are affixed to the outer perimeter of your blade (Figure 4). The diamonds are located in place by the segment, which is a specially formulated combination of metal bond powders and diamond, that have been pressed and heated in a sintering press through the manufacturer. The diamond and bond are tailor-intended to the particular cutting application. The exposed diamonds on the surface from the segment perform cutting. A diamond blade cuts in a manner much like 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 that diamond crystal. Because the blade rotates with the material, the diamonds chip away at the material being cut (Figure 6).
The perfect lifetime of a diamond starts in general crystal that becomes exposed throughout the segment bond matrix. Because the blade begins to cut, a little wear-flat develops plus a bond tail develops behind the diamond. Eventually, small microfractures develop, although the diamond remains cutting well. Then your diamond actually starts to macrofracture, and finally crushes (Figure 7). Here is the last stage of your diamond before it experiences a popout, in which the diamond quite literally pops out of your bond. The blade is constantly function as its cutting action is bought out from the next layer of diamonds that happen to be interspersed during the entire segment.
The metal bond matrix, which can be made of iron, cobalt, nickel, bronze or any other metals in a variety of combinations, was created to wear away after many revolutions of your blade. Its wear rates are designed in order that it will wear at a rate which will provide maximum retention from the diamond crystals and protrusion in the matrix so they can cut.
The diamond and bond come together which is approximately the manufacturer to deliver the best combination in relation to input in the cutting contractor given specific cutting requirements. Critical factors for sides to handle are the bond system, material to become cut and machine parameters. A combination of diamond and bond accomplishes a number of critical functions.