The appropriate consumption of diamond blades is critical to providing cost-effective solutions for that construction industry. The Concrete Sawing and Drilling Association, which happens to be dedicated to the advancement and professionalism of concrete cutting operators, offers operators the equipment 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. Additionally they offer a number of safety and training videos in addition to a safety handbook in support in their effort to educate sawing and drilling operators. This short article will discuss the use of diamond tools, primarily saw blades, and supply tips for their cost-effective use.
Diamond is well known because the hardest substance known to man. One could believe that an operator of cut to length machine could make use of the hardness characteristics of diamond to maximum advantage, i.e. the harder the better. In practice, this may not be always true. If the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear in order to increase the performance in the cutting tool. This information will examine the role diamond plays in cutting tools and the way an operator can make use of analytical methods to maximize the use of the diamond cutting tools thereby increasing productivity and maximizing the lifestyle from the tool.
Diamond crystals might be synthetically grown in a wide variety of qualities, styles and sizes. Synthetic diamond has replaced natural diamond in virtually all construction applications because of this power to tailor-have the diamond for the specific application. Diamond is grown with smooth crystal faces in a cubo-octahedral shape and the color is usually from light yellow to medium yellow-green. Diamond is additionally grown to your specific toughness, which generally increases since the crystal size decreases. How big the diamond crystals, typically called mesh size, determines the number of diamond cutting points exposed on top of a saw blade. On the whole, larger mesh size diamond is utilized for cutting softer materials while smaller mesh size diamond is used for cutting harder materials. However, there are numerous interrelated factors to consider and they general guidelines may well not always apply.
The volume of crystals per volume, or diamond concentration, also affects the cutting performance of the diamond tool. Diamond concentration, typically called CON, is actually a measure of the volume of diamond within a segment in relation to volume. A standard 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 would mean that the tool has 23 carats per cubic inch, or about 4 carats per segment. Increasing the diamond concentration by supplying more cutting points can make the bond act harder as well as increasing diamond tool life. Optimum performance can be accomplished as soon as the diamond tool manufacturer utilizes their experience and analytical capabilities to balance diamond concentration and other factors to obtain optimum performance for your cutting operator.
Diamond Shape & Size
Diamond shapes may 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 often better suited for stone and construction applications. The blocky shape provides greater resistance to fracturing, and thus delivers the maximum number of cutting points and minimum surface contact. It has a direct impact inside a lower horsepower requirement for the EI core cutting machine as well as to increase the life to the tool. Lower grade diamond is less costly and usually has more irregularly shaped and angular crystals which is more designed for less severe applications.
Synthetic diamond can be grown in a range of mesh sizes to fit the required application. Mesh sizes are generally in all the different 20 to 50 Usa Mesh (840 to 297 microns) in construction applications. How big the diamond crystals, and also the concentration, determines the volume of diamond that will be exposed higher than the cutting surface of the segments around the blade. The exposure, or height, of diamond protrusion (Figure 3) influences the depth of cut of every crystal, and subsequently, the possibility material removal rate. Larger diamond crystals and greater diamond protrusion can lead to a potentially faster material removal rate if you have enough horsepower available. Typically, when cutting softer materials, larger diamond crystals are used, and whenever cutting harder materials, smaller crystals are utilized.
The diamond mesh size inside a cutting tool also directly refers to the number of crystals per carat as well as the free cutting ability to the diamond tool. The lesser 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 right mesh size is the task of your diamond tool manufacturer. Producing the correct quantity of cutting points can increase the life of the tool and minimize the device power requirements. As an example, a diamond tool manufacturer may choose to use a finer mesh size to improve the quantity of cutting crystals over a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is just not a similar, and this is especially true for the strength of diamonds used in construction applications. The power of the diamond to resist a positive change load is normally referred to as diamond impact strength. Other diamond-related factors, including crystal shape, size, inclusions and the distribution of these crystal properties, play a role from the impact strength as well.
Impact strength may be measured which is known as Toughness Index (TI). In addition, crystals will also be subjected to extremely high temperatures during manufacturing and sometimes during the cutting process. Thermal Toughness Index (TTI) will be the measure of the capacity of a diamond crystal to stand up to thermal cycling. Subjecting the diamond crystals to high temperature, letting them return to room temperature, and then measuring the modification in toughness makes this measurement useful to a diamond tool manufacturer.
The company must select the right diamond depending on previous experience or input in the operator inside the field. This decision is located, to some extent, about the tool’s design, bond properties, material being cut and Straight core cutting machine. These factors needs to be balanced by selecting diamond grade and concentration that will supply the operator with optimum performance with a suitable cost.
Generally speaking, a larger impact strength is required to get more demanding, harder-to-cut materials. However, always using higher impact strength diamond that is certainly more expensive will not likely always benefit the operator. It might not improve, and may also degrade tool performance.
A diamond saw blade consists of a circular steel disk with segments containing the diamond that are attached to the outer perimeter of your blade (Figure 4). The diamonds are located in place from the segment, which is actually a specially formulated blend of metal bond powders and diamond, which have been pressed and heated inside a sintering press from the manufacturer. The diamond and bond are tailor-made to the specific cutting application. The exposed diamonds at first glance in the segment perform 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 your diamond crystal. As being the blade rotates through the material, the diamonds chip away at the material being cut (Figure 6).
The ideal life of a diamond starts by and large crystal that becomes exposed throughout the segment bond matrix. Since 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 continues to be cutting well. Then your diamond begins to macrofracture, and finally crushes (Figure 7). Here is the last stage of any diamond before it experiences a popout, in which the diamond quite literally pops out of your bond. The blade is constantly serve as its cutting action is taken over by the next layer of diamonds that happen to be interspersed through the segment.
The metal bond matrix, which can be made from iron, cobalt, nickel, bronze or other metals in different combinations, was created to wear away after many revolutions of your blade. Its wear rates are designed to ensure that it will wear at a rate that will provide maximum retention in the diamond crystals and protrusion from the matrix in order to cut.
The diamond and bond come together which is approximately the maker to deliver the ideal combination dependant on input through the cutting contractor given specific cutting requirements. Critical factors for sides to address will be the bond system, material to become cut and machine parameters. The combination of diamond and bond accomplishes numerous critical functions.