The right utilization of diamond blades is critical to providing cost effective solutions to the construction industry. The Concrete Sawing and Drilling Association, which can be focused on the advancement and professionalism of concrete cutting operators, offers operators the equipment and skills required to understand and use diamond blades for optimal performance. CSDA accomplishes this goal through providing introductory and advanced training programs for operators with hands-on education in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. In addition they offer several safety and training videos in addition to a safety handbook in support of their effort to teach sawing and drilling operators. This short article will discuss using diamond tools, primarily saw blades, and give strategies for their inexpensive use.
Diamond is well recognized as being the hardest substance proven to man. One would believe that an operator of Core cutting machine could take advantage of the hardness characteristics of diamond to maximum advantage, i.e. the harder the higher. In practice, 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 in the cutting tool. This post will examine the role diamond plays in cutting tools and how an operator may use analytical techniques to maximize using the diamond cutting tools thereby increasing productivity and maximizing the life span from the tool.
Diamond crystals can be synthetically grown in a wide variety of qualities, shapes and forms. Synthetic diamond has replaced natural diamond in nearly all construction applications for this reason capacity to tailor-make your diamond to the specific application. Diamond is grown with smooth crystal faces within a cubo-octahedral shape and also 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. The size of the diamond crystals, typically called mesh size, determines the number of diamond cutting points exposed on the outside of a saw blade. Generally, larger mesh size diamond is utilized for cutting softer materials while smaller mesh size diamond is used for cutting harder materials. However, there are several interrelated considerations and they general guidelines might not exactly always apply.
The number of crystals per volume, or diamond concentration, also affects the cutting performance of the diamond tool. Diamond concentration, known as CON, is actually a measure of the volume of diamond incorporated into 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 generally in all the different 15-50 CON. A 32 CON would mean that the tool has 23 carats per cubic inch, or about 4 carats per segment. Boosting the diamond concentration by offering more cutting points is likely to 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 / her experience and analytical capabilities to balance diamond concentration as well as other factors to attain optimum performance for the 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 typically more appropriate for stone and construction applications. The blocky shape provides greater potential to deal with fracturing, and so offers the maximum quantity of cutting points and minimum surface contact. This has a direct impact inside a lower horsepower necessity for the Stack core cutting machine as well as maximize the life for the 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 suit the specified application. Mesh sizes are usually in all the different 20 to 50 United states Mesh (840 to 297 microns) in construction applications. The size of the diamond crystals, as well as the concentration, determines the quantity of diamond that can be exposed higher than the cutting surface 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 when there is enough horsepower available. Typically, when cutting softer materials, larger diamond crystals are used, and once cutting harder materials, smaller crystals are being used.
The diamond mesh size within a cutting tool also directly relates to the quantity of crystals per carat and also 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 can have 1,700 crystals per carat.
Specifying the right mesh size is the task of the diamond tool manufacturer. Producing the right amount of cutting points can maximize the lifetime of the tool and reduce the machine power requirements. As an example, a diamond tool manufacturer might want to work with a finer mesh size to increase the number of cutting crystals on the low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is just not the identical, and this is also true for the strength of diamonds employed in construction applications. The ability of a diamond to resist an impact load is normally 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 in the impact strength also.
Impact strength may be measured and is also typically called Toughness Index (TI). Furthermore, crystals can also be put through high temperatures during manufacturing and quite often throughout the cutting process. Thermal Toughness Index (TTI) is definitely the measure of the capacity of any diamond crystal to stand up to thermal cycling. Subjecting the diamond crystals to high temperature, allowing them to return to room temperature, then measuring the modification in toughness makes this measurement useful to a diamond tool manufacturer.
The producer must pick the right diamond based upon previous experience or input in the operator within the field. This decision is located, in part, in the tool’s design, bond properties, material to become cut and Straight core cutting machine. These factors should be balanced by picking diamond grade and concentration that may provide the operator with optimum performance in a suitable cost.
Generally speaking, a better impact strength is essential for more demanding, harder-to-cut materials. However, always using higher impact strength diamond that is higher priced is not going to always help the operator. It may possibly not improve, and can even 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 from the blade (Figure 4). The diamonds are located in place from the segment, and that is a specially formulated blend of metal bond powders and diamond, that have been pressed and heated within a sintering press by 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 much like 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 the diamond crystal. Because the blade rotates throughout the material, the diamonds chip away with the material being cut (Figure 6).
The ideal lifetime of a diamond starts by and large crystal that becomes exposed with the segment bond matrix. Because the blade starts to cut, a small wear-flat develops and a bond tail develops behind the diamond. Eventually, small microfractures develop, however the diamond is still cutting well. Then the diamond actually starts to macrofracture, and in the end crushes (Figure 7). Here is the last stage of any diamond before it experiences a popout, in which the diamond quite literally pops out from the bond. The blade will continue to serve as its cutting action is bought out from the next layer of diamonds which can be interspersed through the segment.
The metal bond matrix, that may be created from iron, cobalt, nickel, bronze or another 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 for a price that will provide maximum retention of your diamond crystals and protrusion in the matrix to enable them to cut.
The diamond and bond come together and is particularly approximately the company to provide the ideal combination dependant on input in the cutting contractor given specific cutting requirements. Critical factors for sides to deal with are the bond system, material to be cut and machine parameters. A combination of diamond and bond accomplishes numerous critical functions.