The right usage of diamond blades is critical to providing cost-effective solutions to the construction industry. The Concrete Sawing and Drilling Association, which can be dedicated to the advancement and professionalism of concrete cutting operators, offers operators the various tools and skills essential to understand and employ diamond blades for optimal performance. CSDA accomplishes this goal by offering introductory and advanced training programs for operators with hands-on learning flat sawing, wall sawing, core drilling, wire sawing and hand sawing. In addition they offer some safety and training videos together with a safety handbook in support of the effort to coach sawing and drilling operators. This post will discuss the use of diamond tools, primarily saw blades, and provide recommendations for their inexpensive use.
Diamond is well known as the hardest substance proven to man. One could assume that an operator of Core cutting 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. Regardless of if the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear in order to maximize the performance in the cutting tool. This article will examine the role diamond plays in cutting tools and how an operator can make use of analytical ways to maximize using the diamond cutting tools thereby increasing productivity and maximizing the lifestyle in the tool.
Diamond crystals can be synthetically grown in a multitude of qualities, sizes and shapes. Synthetic diamond has replaced natural diamond in almost all construction applications due to this capability to tailor-make your diamond to the specific application. Diamond is grown with smooth crystal faces inside a cubo-octahedral shape and the color is usually from light yellow to medium yellow-green. Diamond is likewise grown to a specific toughness, which generally increases as being the crystal size decreases. How big the diamond crystals, typically called mesh size, determines the amount of diamond cutting points exposed on top of any saw blade. Generally speaking, larger mesh size diamond is utilized for cutting softer materials while smaller mesh size diamond can be used for cutting harder materials. However, there are many interrelated factors to consider and those general guidelines might not always apply.
The number of crystals per volume, or diamond concentration, also affects the cutting performance from the diamond tool. Diamond concentration, typically called CON, can be a way of measuring the amount of diamond found in a segment based on volume. A common reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is typically 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. Boosting the diamond concentration by providing more cutting points can certainly make the bond act harder while increasing diamond tool life. Optimum performance can be achieved as soon as the diamond tool manufacturer utilizes their experience and analytical capabilities to balance diamond concentration and also other factors to obtain 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 typically better suited for stone and construction applications. The blocky shape provides greater resistance to fracturing, and thus supplies the maximum quantity of cutting points and minimum surface contact. It has a direct impact in the lower horsepower requirement of the EI core cutting machine and to increase the life for your tool. Lower grade diamond is less costly and customarily has more irregularly shaped and angular crystals and it is more designed for less severe applications.
Synthetic diamond might be grown in many different mesh sizes to fit the preferred application. Mesh sizes are usually in the plethora of 20 to 50 United states Mesh (840 to 297 microns) in construction applications. The actual size of the diamond crystals, and also the concentration, determines the volume of diamond that will be exposed higher than 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 opportunity material removal rate. Larger diamond crystals and greater diamond protrusion will result in a potentially faster material removal rate should there be enough horsepower available. As a general rule, when cutting softer materials, larger diamond crystals are employed, and whenever cutting harder materials, smaller crystals are used.
The diamond mesh size within a cutting tool also directly relates to the amount of crystals per carat as well as the free cutting ability of the diamond tool. 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 will have 1,700 crystals per carat.
Specifying the right mesh dimension is the work of the diamond tool manufacturer. Producing the correct number of cutting points can increase 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 increase the quantity of cutting crystals on the low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is just not a similar, and this is especially valid for the strength of diamonds found in construction applications. The capacity of a diamond to withstand a positive change load is normally called diamond impact strength. Other diamond-related factors, like crystal shape, size, inclusions along with the distribution of the crystal properties, be a factor from the impact strength also.
Impact strength could be measured and is commonly referred to as Toughness Index (TI). Additionally, crystals will also be subjected to extremely high temperatures during manufacturing and sometimes in the cutting process. Thermal Toughness Index (TTI) is definitely the measure of the power 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 alteration in toughness makes this measurement beneficial to a diamond tool manufacturer.
The manufacturer must select the right diamond depending on previous experience or input in the operator inside the field. This decision is situated, to some extent, in the tool’s design, bond properties, material to become cut and Silicon steel core cutting machine. These factors needs to be balanced by your selection of diamond grade and concentration that will provide the operator with optimum performance in a suitable cost.
In general, a better impact strength is required for further demanding, harder-to-cut materials. However, always using higher impact strength diamond that is more expensive is not going to always help the operator. It may not improve, and may also degrade tool performance.
A diamond saw blade comprises 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 with the segment, and that is a specially formulated blend 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-made to the precise cutting application. The exposed diamonds at first glance from the segment do the cutting. A diamond blade cuts within a manner much like 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 that diamond crystal. Since the blade rotates throughout the material, the diamonds chip away with the material being cut (Figure 6).
The perfect lifetime of a diamond starts in general crystal that becomes exposed from the segment bond matrix. As being the blade actually starts to cut, a small wear-flat develops and a bond tail develops behind the diamond. Eventually, small microfractures develop, but the diamond is still cutting well. Then this diamond begins to macrofracture, and eventually crushes (Figure 7). Here is the last stage of a diamond before it experiences a popout, the location where the diamond quite literally pops out from the bond. The blade continues to act as its cutting action is bought out through the next layer of diamonds which can be interspersed throughout the segment.
The metal bond matrix, which is often made from iron, cobalt, nickel, bronze or some other metals in various combinations, was 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 may provide maximum retention of the diamond crystals and protrusion from your matrix so they can cut.
The diamond and bond interact with each other which is around the company to supply the very best combination based upon input through the cutting contractor given specific cutting requirements. Critical factors for both sides to address would be the bond system, material being cut and machine parameters. The combination of diamond and bond accomplishes a variety of critical functions.