The right usage of diamond blades is essential to providing cost effective solutions for the construction industry. The Concrete Sawing and Drilling Association, which is focused on the advancement and professionalism of concrete cutting operators, offers operators the instruments and skills essential to understand and make use of diamond blades for optimal performance. CSDA accomplishes this goal through providing introductory and advanced training programs for operators with hands-on training in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. They also offer some safety and training videos together with a safety handbook in support with their effort to coach sawing and drilling operators. This post will discuss the use of diamond tools, primarily saw blades, and provide recommendations for their cost-effective use.
Diamond is well recognized because the hardest substance known to man. One could feel that an operator of Core cutting machine could make use of the hardness characteristics of diamond to maximum advantage, i.e. the harder the greater. In practice, this may not be always true. Whether or not 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 just how an operator can make use of analytical techniques to maximize using the diamond cutting tools thereby increasing productivity and maximizing the life from the tool.
Diamond crystals might be synthetically grown in a multitude of qualities, sizes and shapes. Synthetic diamond has replaced natural diamond in almost all construction applications as a result power to tailor-make your diamond for the specific application. Diamond is grown with smooth crystal faces in a cubo-octahedral shape along with the color is usually from light yellow to medium yellow-green. Diamond is additionally grown to a specific toughness, which generally increases since the crystal size decreases. The dimensions of the diamond crystals, typically called mesh size, determines the volume of diamond cutting points exposed on top of your saw blade. On the whole, larger mesh size diamond is 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 of the diamond tool. Diamond concentration, known as CON, can be a measure of the quantity of diamond contained in a segment dependant on volume. A common reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is typically in the plethora of 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 through providing more cutting points can certainly make the bond act harder as well as increasing diamond tool life. Optimum performance may be accomplished as soon as the diamond tool manufacturer utilizes his or her experience and analytical capabilities to balance diamond concentration along with other factors to attain optimum performance for the cutting operator.
Diamond Shape & Size
Diamond shapes can 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 potential to deal with fracturing, and so provides the maximum amount of cutting points and minimum surface contact. This has a direct impact in the lower horsepower necessity for the EI core cutting machine and also to maximize the life for your tool. Lower grade diamond is cheaper 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 put the specified application. Mesh sizes are often in the plethora of 20 to 50 Usa Mesh (840 to 297 microns) in construction applications. How big the diamond crystals, plus the concentration, determines the volume of diamond that can be exposed higher than the cutting surface 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 should there be enough horsepower available. For the most part, when cutting softer materials, larger diamond crystals are being used, so when cutting harder materials, smaller crystals are being used.
The diamond mesh size within a cutting tool also directly refers to the amount of crystals per carat along with the free cutting capability of the diamond tool. The 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 could have 1,700 crystals per carat.
Specifying the appropriate mesh dimensions are the job from the diamond tool manufacturer. Producing the best number of cutting points can maximize the life of the tool and reduce the appliance power requirements. As one example, a diamond tool manufacturer may choose to make use of a finer mesh size to improve the amount of cutting crystals on the low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is not the same, and this is also true for the potency of diamonds employed in construction applications. The power of your diamond to resist a direct impact load is typically called diamond impact strength. Other diamond-related factors, including crystal shape, size, inclusions as well as the distribution of these crystal properties, be involved from the impact strength also.
Impact strength may be measured and is also commonly referred to as Toughness Index (TI). Furthermore, crystals can also be put through extremely high temperatures during manufacturing and sometimes throughout the cutting process. Thermal Toughness Index (TTI) may be the way of measuring the capacity of a diamond crystal to stand up to thermal cycling. Subjecting the diamond crystals to high temperature, permitting them to return to room temperature, and after that measuring the modification in toughness makes this measurement useful to a diamond tool manufacturer.
The manufacturer must pick the best diamond based upon previous experience or input in the operator within the field. This decision is based, to some extent, about the tool’s design, bond properties, material to become cut and Silicon steel core cutting machine. These factors needs to be balanced by selecting diamond grade and concentration that will supply the operator with optimum performance at the suitable cost.
Generally, an increased impact strength is required for further demanding, harder-to-cut materials. However, always using higher impact strength diamond which is more costly will not likely always benefit the operator. It may not improve, and may also degrade tool performance.
A diamond saw blade is composed of a circular steel disk with segments containing the diamond that are connected to the outer perimeter of the blade (Figure 4). The diamonds are located in place from the segment, that is a specially formulated combination of metal bond powders and diamond, which have been pressed and heated in the sintering press by the manufacturer. The diamond and bond are tailor-designed to the particular cutting application. The exposed diamonds on the surface of your segment do the cutting. A diamond blade cuts within a manner comparable to 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 from the material, the diamonds chip away with the material being cut (Figure 6).
The optimal lifetime of a diamond starts in general crystal that becomes exposed through the segment bond matrix. Because the blade begins to cut, a small wear-flat develops along with a bond tail develops behind the diamond. Eventually, small microfractures develop, nevertheless the diamond is still cutting well. Then the diamond actually starts to macrofracture, and in the end crushes (Figure 7). This is actually the last stage of the diamond before it experiences a popout, the location where the diamond quite literally pops out of your bond. The blade will continue to function as its cutting action is taken over through the next layer of diamonds that are interspersed during the entire segment.
The metal bond matrix, that may be manufactured from iron, cobalt, nickel, bronze or some other metals in different combinations, is designed to wear away after many revolutions from the blade. Its wear rate is designed in order that it will wear at a rate that will provide maximum retention from the diamond crystals and protrusion from your matrix to enable them to cut.
The diamond and bond interact which is approximately the maker to supply the ideal combination based on input from the cutting contractor given specific cutting requirements. Critical factors for both sides to manage are the bond system, material to be cut and machine parameters. The combination of diamond and bond accomplishes a number of critical functions.