The proper use of diamond blades is vital to providing economical solutions to the construction industry. The Concrete Sawing and Drilling Association, which is committed to the advancement and professionalism of concrete cutting operators, offers operators the instruments and skills required 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 learning flat sawing, wall sawing, core drilling, wire sawing and hand sawing. They also offer a series of safety and training videos and also a safety handbook in support with their effort to teach sawing and drilling operators. This post will discuss using diamond tools, primarily saw blades, and offer ideas for their cost-effective use.
Diamond is well recognized as the hardest substance recognized to man. One could think 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 not always true. If the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear as a way to maximize the performance of your cutting tool. This information will examine the role diamond plays in cutting tools and exactly how an operator can use analytical ways to maximize the usage of the diamond cutting tools thereby increasing productivity and maximizing the life span of your tool.
Diamond crystals might be synthetically grown in a multitude of qualities, shapes and forms. Synthetic diamond has replaced natural diamond in practically all construction applications because of this capacity to tailor-create the diamond for that specific application. Diamond is grown with smooth crystal faces inside a cubo-octahedral shape as well as the color is generally from light yellow to medium yellow-green. Diamond is likewise grown to some specific toughness, which generally increases because the crystal size decreases. How big the diamond crystals, known as mesh size, determines the quantity of diamond cutting points exposed on the surface of the saw blade. On the whole, larger mesh size diamond can be used for cutting softer materials while smaller mesh size diamond is used for cutting harder materials. However, there are many interrelated things to consider and those general guidelines may well not always apply.
The quantity of crystals per volume, or diamond concentration, also affects the cutting performance from the diamond tool. Diamond concentration, typically called CON, is a measure of the level of diamond found in a segment based upon volume. A typical 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. Increasing the diamond concentration by providing more cutting points can certainly make the bond act harder while also 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 to the 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 usually more appropriate for stone and construction applications. The blocky shape provides greater resistance to fracturing, and therefore delivers the maximum variety of cutting points and minimum surface contact. This has a direct impact within a lower horsepower requirement for the transformer core cutting machine and also to increase the life for the tool. Lower grade diamond is cheaper and usually has more irregularly shaped and angular crystals and it is more suitable for less severe applications.
Synthetic diamond may be grown in a variety of mesh sizes to put the required application. Mesh sizes are usually in all the different 20 to 50 U.S. Mesh (840 to 297 microns) in construction applications. The dimensions of the diamond crystals, plus the concentration, determines the volume of diamond that can be exposed over the cutting top of the segments about the blade. The exposure, or height, of diamond protrusion (Figure 3) influences the depth of cut for each crystal, and subsequently, the opportunity material removal rate. Larger diamond crystals and greater diamond protrusion will lead to a potentially faster material removal rate when there is enough horsepower available. As a general rule, when cutting softer materials, larger diamond crystals are employed, and once cutting harder materials, smaller crystals are utilized.
The diamond mesh size in a cutting tool also directly refers to the volume of crystals per carat along with the free cutting capability of the diamond tool. The lesser 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 appropriate mesh dimension is the position from the diamond tool manufacturer. Producing the right number of cutting points can maximize the life of the tool and minimize the machine power requirements. As one example, a diamond tool manufacturer may choose to utilize a finer mesh size to boost 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 especially valid for the effectiveness of diamonds used in construction applications. The capability of your diamond to withstand an effect load is generally referred to as diamond impact strength. Other diamond-related factors, like crystal shape, size, inclusions as well as the distribution of those crystal properties, play a role from the impact strength as well.
Impact strength might be measured and is also known as Toughness Index (TI). Moreover, crystals will also be exposed to extremely high temperatures during manufacturing and in some cases in the cutting process. Thermal Toughness Index (TTI) will be the measure of the capability of the diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, permitting them to return to room temperature, after which measuring the change in toughness makes this measurement useful to a diamond tool manufacturer.
The maker must select the right diamond according to previous experience or input through the operator in the field. This decision relies, in part, around the tool’s design, bond properties, material to get cut and Straight core cutting machine. These factors must be balanced by your selection of diamond grade and concentration that may provide 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 which is more pricey will never always help the operator. It might 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 in the blade (Figure 4). The diamonds are located in place from the segment, which is a specially formulated combination of metal bond powders and diamond, that were pressed and heated inside a sintering press through the manufacturer. The diamond and bond are tailor-designed to the particular cutting application. The exposed diamonds on the surface in the segment carry out the cutting. A diamond blade cuts in the manner just like how sand paper cuts wood. As being the blade cuts, bond tails are formed dexqpky76 trail behind each diamond (Figure 5). This bond tail provides mechanical support for that diamond crystal. As being the blade rotates with the material, the diamonds chip away with the material being cut (Figure 6).
The optimal lifetime of a diamond starts by and large crystal that becomes exposed through the segment bond matrix. Because the blade starts to cut, a small wear-flat develops plus a bond tail develops behind the diamond. Eventually, small microfractures develop, nevertheless the diamond continues to be cutting well. Then your diamond starts to macrofracture, and in the end crushes (Figure 7). Here is the last stage of the diamond before it experiences a popout, where the diamond quite literally pops from the bond. The blade consistently function as its cutting action is bought out with the next layer of diamonds that happen to be interspersed through the segment.
The metal bond matrix, which is often manufactured from iron, cobalt, nickel, bronze or any other metals in a variety of combinations, is made to wear away after many revolutions from the blade. Its wear rates are designed so that it will wear at a rate which will provide maximum retention of the diamond crystals and protrusion through the matrix so they can cut.
The diamond and bond interact in fact it is around the maker to provide the best combination dependant on input through the cutting contractor given specific cutting requirements. Critical factors both for sides to manage will be the bond system, material to be cut and machine parameters. A combination of diamond and bond accomplishes numerous critical functions.