The correct consumption of diamond blades is vital to providing economical solutions to the construction industry. The Concrete Sawing and Drilling Association, that is focused on the advancement and professionalism of concrete cutting operators, offers operators the various tools and skills needed 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 education in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. They also offer several safety and training videos as well as a safety handbook in support in their effort to coach sawing and drilling operators. This short article will discuss using diamond tools, primarily saw blades, and supply recommendations for their inexpensive use.
Diamond is well recognized as being the hardest substance proven to man. One could believe that an operator of cut to length machine could use the hardness characteristics of diamond to maximum advantage, i.e. the harder the higher. In practice, this is simply not always true. Regardless of if the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear to be able to maximize the performance from the cutting tool. This short article will examine the role diamond plays in cutting tools and exactly how an operator can use analytical ways to maximize using the diamond cutting tools thereby increasing productivity and maximizing the life span of the tool.
Diamond crystals can be synthetically grown in a multitude of qualities, styles and sizes. Synthetic diamond has replaced natural diamond in virtually all construction applications because of this capability to tailor-have the diamond to the specific application. Diamond is grown with smooth crystal faces in the cubo-octahedral shape along with the color is generally from light yellow to medium yellow-green. Diamond can also be 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 volume of diamond cutting points exposed at first glance of any saw blade. Generally, larger mesh size diamond is utilized for cutting softer materials while smaller mesh size diamond is commonly used for cutting harder materials. However, there are numerous interrelated considerations and these general guidelines might not always apply.
The quantity of crystals per volume, or diamond concentration, also affects the cutting performance of your diamond tool. Diamond concentration, commonly referred to as CON, is a way of measuring the amount of diamond found in a segment dependant on volume. A typical reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is normally in the range of 15-50 CON. A 32 CON means the tool has 23 carats per cubic inch, or about 4 carats per segment. Improving the diamond concentration by providing more cutting points is likely to make the bond act harder while increasing diamond tool life. Optimum performance may be accomplished if the diamond tool manufacturer utilizes her or his experience and analytical capabilities to balance diamond concentration as well as other factors to attain optimum performance for that cutting operator.
Diamond Shape & Size
Diamond shapes may vary 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 more appropriate for stone and construction applications. The blocky shape provides greater resistance to fracturing, and thus supplies the maximum amount of cutting points and minimum surface contact. This has a direct impact in the lower horsepower necessity for the Stack core cutting machine and also to increase the life for that tool. Lower grade diamond is less costly and generally has more irregularly shaped and angular crystals and is more suitable for less severe applications.
Synthetic diamond could be grown in a range of mesh sizes to put the required application. Mesh sizes are typically in the range 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 volume of diamond that might be exposed on top of the cutting surface of the segments on the blade. The exposure, or height, of diamond protrusion (Figure 3) influences the depth of cut of each and every crystal, and subsequently, the possibility material removal rate. Larger diamond crystals and greater diamond protrusion will result in a potentially faster material removal rate if you find enough horsepower available. Typically, when cutting softer materials, larger diamond crystals are employed, and whenever cutting harder materials, smaller crystals are employed.
The diamond mesh size inside a cutting tool also directly concerns the volume of crystals per carat as well as the free cutting capacity for the diamond tool. The smaller the mesh size, the larger 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 could have 1,700 crystals per carat.
Specifying the proper mesh dimension is the task of the diamond tool manufacturer. Producing the proper amount 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 boost the quantity of cutting crystals with a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is just not the identical, and this is also true for the effectiveness of diamonds used in construction applications. The capability of a diamond to resist an impact load is typically termed as diamond impact strength. Other diamond-related factors, like crystal shape, size, inclusions and the distribution of these crystal properties, are involved within the impact strength at the same time.
Impact strength could be measured and is also typically called Toughness Index (TI). In addition, crystals can also be exposed to very high temperatures during manufacturing and in some cases throughout the cutting process. Thermal Toughness Index (TTI) will be the measure of the ability of a diamond crystal to stand up to thermal cycling. Subjecting the diamond crystals to high temperature, allowing them to come back to room temperature, and after that measuring the modification in toughness makes this measurement beneficial to a diamond tool manufacturer.
The company must pick the best diamond based on previous experience or input from the operator inside the field. This decision is based, in part, about the tool’s design, bond properties, material to be cut and Straight core cutting machine. These factors must be balanced by the selection of diamond grade and concentration that will supply the operator with optimum performance in a suitable cost.
On the whole, a better impact strength is essential for further demanding, harder-to-cut materials. However, always using higher impact strength diamond that may be higher priced will not always benefit the operator. It may possibly not improve, and may even degrade tool performance.
A diamond saw blade consists of a circular steel disk with segments containing the diamond that are affixed to the outer perimeter of the blade (Figure 4). The diamonds are kept in place by the segment, which is actually a specially formulated blend of metal bond powders and diamond, that have been pressed and heated in the sintering press with the manufacturer. The diamond and bond are tailor-made to the particular cutting application. The exposed diamonds on the outside from the segment do the cutting. A diamond blade cuts in a manner comparable to how sand paper cuts wood. Because the blade cuts, bond tails are formed dexqpky76 trail behind each diamond (Figure 5). This bond tail provides mechanical support for the diamond crystal. As being the blade rotates from the material, the diamonds chip away at the material being cut (Figure 6).
The best lifetime of a diamond starts overall crystal that becomes exposed with the segment bond matrix. Because the blade actually starts to cut, a tiny wear-flat develops and a bond tail develops behind the diamond. Eventually, small microfractures develop, although the diamond is still cutting well. Then this diamond actually starts to macrofracture, and eventually crushes (Figure 7). Here is the last stage of the diamond before it experiences a popout, where diamond quite literally pops out from the bond. The blade will continue to serve as its cutting action is bought out with the next layer of diamonds which can be interspersed throughout the segment.
The metal bond matrix, which can be created from iron, cobalt, nickel, bronze or some other metals in a variety of combinations, is designed to wear away after many revolutions in the blade. Its wear rate is designed so that it will wear at a rate that can provide maximum retention of your diamond crystals and protrusion through the matrix so they can cut.
The diamond and bond interact and it is around the maker to provide the very best combination based on input from the cutting contractor given specific cutting requirements. Critical factors for both sides to handle will be the bond system, material being cut and machine parameters. The combination of diamond and bond accomplishes numerous critical functions.