The right usage of diamond blades is critical to providing cost effective solutions for your construction industry. The Concrete Sawing and Drilling Association, that is dedicated to the advancement and professionalism of concrete cutting operators, offers operators the instruments and skills required to understand and employ diamond blades for optimal performance. CSDA accomplishes this goal by providing introductory and advanced training programs for operators with hands-on learning flat sawing, wall sawing, core drilling, wire sawing and hand sawing. Additionally, they offer several safety and training videos together with a safety handbook in support of their effort to teach sawing and drilling operators. This information will discuss the application of diamond tools, primarily saw blades, and give strategies for their inexpensive use.
Diamond is well known since the hardest substance seen to man. One could believe that an operator of cut to length machine could utilize the hardness characteristics of diamond to maximum advantage, i.e. the harder the greater. In reality, this is simply not always true. Whether or not 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 short article will examine the role diamond plays in cutting tools and how an operator may use analytical methods to maximize using the diamond cutting tools thereby increasing productivity and maximizing the life span in the tool.
Diamond crystals could be synthetically grown in a multitude of qualities, sizes and shapes. Synthetic diamond has replaced natural diamond in practically all construction applications due to this ability to tailor-make your diamond for your specific application. Diamond is grown with smooth crystal faces in the cubo-octahedral shape as well as the color is generally from light yellow to medium yellow-green. Diamond is likewise grown to a specific toughness, which generally increases as being the crystal size decreases. The actual size of the diamond crystals, known as mesh size, determines the volume of diamond cutting points exposed at first glance of a saw blade. Generally, larger mesh size diamond can be used for cutting softer materials while smaller mesh size diamond is utilized for cutting harder materials. However, there are several interrelated considerations and those general guidelines might not exactly always apply.
The amount of crystals per volume, or diamond concentration, also affects the cutting performance of your diamond tool. Diamond concentration, known as CON, is actually a way of measuring the volume of diamond within a segment in relation to volume. A frequent reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is usually in all the different 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 supplying more cutting points can make the bond act harder as well as increasing diamond tool life. Optimum performance is possible once the diamond tool manufacturer utilizes their experience and analytical capabilities to balance diamond concentration along with other factors to obtain optimum performance for your cutting operator.
Diamond Shape & Size
Diamond shapes can 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 potential to deal with fracturing, and therefore offers the maximum variety of cutting points and minimum surface contact. It has a direct impact inside a lower horsepower need for the Stack core cutting machine as well as to increase the life for that tool. Lower grade diamond is less costly and usually has more irregularly shaped and angular crystals and is also more suited for less severe applications.
Synthetic diamond could be grown in a range of mesh sizes to fit the desired application. Mesh sizes are typically in the range of 20 to 50 United states Mesh (840 to 297 microns) in construction applications. The dimensions of the diamond crystals, plus the concentration, determines the level of diamond that might be exposed higher than the cutting top 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 possible material removal rate. Larger diamond crystals and greater diamond protrusion will lead to a potentially faster material removal rate should there be enough horsepower available. On the whole, when cutting softer materials, larger diamond crystals are used, and whenever cutting harder materials, smaller crystals are being used.
The diamond mesh size inside a cutting tool also directly concerns the quantity of crystals per carat and the free cutting capability of the diamond tool. Small 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 work from the diamond tool manufacturer. Producing the proper number of cutting points can maximize the life of the tool and minimize the device power requirements. For instance, a diamond tool manufacturer may choose to use a finer mesh size to enhance the number of cutting crystals over a 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 effectiveness of diamonds employed in construction applications. The power of a diamond to withstand a direct impact load is generally known as diamond impact strength. Other diamond-related factors, for example crystal shape, size, inclusions and also the distribution of the crystal properties, be a factor inside the impact strength also.
Impact strength can be measured which is known as Toughness Index (TI). Additionally, crystals can also be subjected to quite high temperatures during manufacturing and quite often throughout the cutting process. Thermal Toughness Index (TTI) is the way of measuring the capability of a diamond crystal to resist thermal cycling. Subjecting the diamond crystals to high temperature, permitting them to return to room temperature, and after that measuring the change in toughness makes this measurement necessary to a diamond tool manufacturer.
The maker must pick the right diamond based on previous experience or input from the operator within the field. This decision is situated, partly, about the tool’s design, bond properties, material to become cut and Straight core cutting machine. These factors has to be balanced by selecting diamond grade and concentration that may provide you with the operator with optimum performance with a suitable cost.
Generally, a greater impact strength is essential for further demanding, harder-to-cut materials. However, always using higher impact strength diamond that is higher priced will not likely always benefit the operator. It may 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 your blade (Figure 4). The diamonds are located in place by the segment, which is actually a specially formulated combination of metal bond powders and diamond, which have been pressed and heated in the sintering press through the manufacturer. The diamond and bond are tailor-created to the specific cutting application. The exposed diamonds on the surface from the segment do the cutting. A diamond blade cuts within a manner similar to how sand paper cuts wood. Since the blade cuts, bond tails are formed dexqpky76 trail behind each diamond (Figure 5). This bond tail provides mechanical support for your diamond crystal. As being the blade rotates with the material, the diamonds chip away with the material being cut (Figure 6).
The ideal life of a diamond starts in general crystal that becomes exposed through the segment bond matrix. As being the blade begins to cut, a small wear-flat develops and a bond tail develops behind the diamond. Eventually, small microfractures develop, however the diamond remains cutting well. Then a diamond starts to macrofracture, and finally crushes (Figure 7). This is basically the last stage of your diamond before it experiences a popout, in which the diamond quite literally pops from the bond. The blade consistently function as its cutting action is bought out through the next layer of diamonds that are interspersed through the entire segment.
The metal bond matrix, that may be manufactured from iron, cobalt, nickel, bronze or any other metals in different combinations, is designed to wear away after many revolutions of the blade. Its wear rates are designed so that it will wear at a rate which will provide maximum retention in the diamond crystals and protrusion from your matrix to enable them to cut.
The diamond and bond interact with each other in fact it is as much as the maker to provide the best combination in relation to input from the cutting contractor given specific cutting requirements. Critical factors for both sides to handle would be the bond system, material to become cut and machine parameters. The combination of diamond and bond accomplishes several critical functions.