The appropriate usage of diamond blades is essential to providing cost effective solutions for your construction industry. The Concrete Sawing and Drilling Association, which can be dedicated to the advancement and professionalism of concrete cutting operators, offers operators the tools and skills required to understand and use diamond blades for optimal performance. CSDA accomplishes this goal by providing introductory and advanced training programs for operators with hands-on lessons in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. They also offer several safety and training videos in addition to a safety handbook in support of the effort to educate sawing and drilling operators. This post will discuss the usage of diamond tools, primarily saw blades, and supply tips for their inexpensive use.
Diamond is well recognized since the hardest substance proven to man. One would think that an operator of cut to length machine could take advantage of the hardness characteristics of diamond to maximum advantage, i.e. the harder the higher. 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 as a way to maximize the performance from the cutting tool. This short article will examine the role diamond plays in cutting tools and the way an operator may use analytical techniques to maximize using the diamond cutting tools thereby increasing productivity and maximizing the lifestyle of your tool.
Diamond crystals may be synthetically grown in numerous types of qualities, sizes and shapes. Synthetic diamond has replaced natural diamond in virtually all construction applications for this reason capability to tailor-make your diamond to the specific application. Diamond is grown with smooth crystal faces in the cubo-octahedral shape as well as the color is usually from light yellow to medium yellow-green. Diamond is also grown to a specific toughness, which generally increases as the crystal size decreases. How big the diamond crystals, commonly referred to as mesh size, determines the number of diamond cutting points exposed on the surface of your 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 several interrelated considerations and these general guidelines might not exactly always apply.
The amount of crystals per volume, or diamond concentration, also affects the cutting performance in the diamond tool. Diamond concentration, known as CON, can be a measure of the amount of diamond within 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 range of 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 supplying more cutting points can make the bond act harder while increasing diamond tool life. Optimum performance can be achieved once the diamond tool manufacturer utilizes her or his experience and analytical capabilities to balance diamond concentration along with other factors to attain 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 usually better suited for stone and construction applications. The blocky shape provides greater resistance to fracturing, and thus provides the maximum number of cutting points and minimum surface contact. This has a direct impact in a lower horsepower requirement of the transformer core cutting machine as well as to increase the life for your tool. Lower grade diamond is less costly and usually has more irregularly shaped and angular crystals and is more suitable for less severe applications.
Synthetic diamond may be grown in a variety of mesh sizes to put the preferred application. Mesh sizes are generally in all the different 20 to 50 Usa Mesh (840 to 297 microns) in construction applications. The dimensions of the diamond crystals, plus the concentration, determines the quantity of diamond that will be exposed over the cutting surface of the segments in the blade. The exposure, or height, of diamond protrusion (Figure 3) influences the depth of cut of each crystal, and subsequently, the possible material removal rate. Larger diamond crystals and greater diamond protrusion can result in a potentially faster material removal rate should there be enough horsepower available. For the most part, when cutting softer materials, larger diamond crystals are used, so when cutting harder materials, smaller crystals are being used.
The diamond mesh size inside a cutting tool also directly refers to the volume of crystals per carat along with the free cutting capacity for 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 may have 1,700 crystals per carat.
Specifying the right mesh dimension is the work in the diamond tool manufacturer. Producing the best variety of cutting points can maximize the life of the tool and minimize the device power requirements. For example, a diamond tool manufacturer may choose to utilize a finer mesh size to boost the volume of cutting crystals with a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is not a similar, and this is especially true for the potency of diamonds used in construction applications. The capacity of your diamond to withstand a direct impact load is normally referred to as diamond impact strength. Other diamond-related factors, for example crystal shape, size, inclusions and also the distribution of those crystal properties, play a role within the impact strength as well.
Impact strength might be measured and is known as Toughness Index (TI). Additionally, crystals will also be exposed to high temperatures during manufacturing and in some cases throughout the cutting process. Thermal Toughness Index (TTI) may be the measure of the ability of any diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, letting them go back to room temperature, and after that measuring the change in toughness makes this measurement helpful to a diamond tool manufacturer.
The manufacturer must select the right diamond based upon previous experience or input through the operator from the field. This decision is located, in part, in the tool’s design, bond properties, material to be cut and Straight core cutting machine. These factors should be balanced by picking diamond grade and concentration which will supply the operator with optimum performance at the suitable cost.
On the whole, a better impact strength is necessary for further demanding, harder-to-cut materials. However, always using higher impact strength diamond which is more costly will not always benefit the operator. It may possibly not improve, and may also degrade tool performance.
A diamond saw blade comprises a circular steel disk with segments containing the diamond that are connected to the outer perimeter in the blade (Figure 4). The diamonds are located in place from the segment, which is a specially formulated blend of metal bond powders and diamond, which have been pressed and heated in a sintering press from the manufacturer. The diamond and bond are tailor-intended to the specific cutting application. The exposed diamonds on the surface of the segment carry out the cutting. A diamond blade cuts inside 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 that diamond crystal. As being the blade rotates with the material, the diamonds chip away in the material being cut (Figure 6).
The best lifetime of a diamond starts as a whole crystal that becomes exposed through the segment bond matrix. As the blade starts to cut, a little wear-flat develops plus a bond tail develops behind the diamond. Eventually, small microfractures develop, nevertheless the diamond is still cutting well. Then a diamond starts to macrofracture, and ultimately crushes (Figure 7). This is actually the last stage of any diamond before it experiences a popout, where the diamond quite literally pops out from the bond. The blade consistently serve as its cutting action is bought out through the next layer of diamonds that happen to be interspersed during the entire segment.
The metal bond matrix, which may be made of iron, cobalt, nickel, bronze or any other metals in several combinations, was created to wear away after many revolutions from the blade. Its wear rate is designed so that it will wear at a rate that will provide maximum retention from the diamond crystals and protrusion from the matrix to enable them to cut.
The diamond and bond interact which is as much as the maker to supply the very best combination in relation to input in the cutting contractor given specific cutting requirements. Critical factors for sides to deal with will be the bond system, material to become cut and machine parameters. The combination of diamond and bond accomplishes numerous critical functions.