The proper usage of diamond blades is critical to providing cost-effective solutions for the construction industry. The Concrete Sawing and Drilling Association, which is dedicated to the advancement and professionalism of concrete cutting operators, offers operators the instruments and skills needed to understand and utilize diamond blades for optimal performance. CSDA accomplishes this goal by giving introductory and advanced training programs for operators with hands-on lessons in 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 with their effort to teach sawing and drilling operators. This information will discuss using diamond tools, primarily saw blades, and offer recommendations for their cost-effective use.
Diamond is well known as being the hardest substance known to man. One would believe that an operator of cut to length machine could utilize the hardness characteristics of diamond to maximum advantage, i.e. the harder the more effective. In practice, this is simply not always true. Whether the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear as a way to increase the performance of your cutting tool. This post will examine the role diamond plays in cutting tools and exactly how an operator can make use of analytical solutions to maximize using the diamond cutting tools thereby increasing productivity and maximizing the lifestyle from the tool.
Diamond crystals may be synthetically grown in numerous types of qualities, styles and sizes. Synthetic diamond has replaced natural diamond in virtually all construction applications for this reason ability to tailor-have the diamond for the specific application. Diamond is grown with smooth crystal faces in the cubo-octahedral shape along with the color is typically from light yellow to medium yellow-green. Diamond can also be grown into a specific toughness, which generally increases as the crystal size decreases. How big the diamond crystals, commonly referred to as mesh size, determines the amount of diamond cutting points exposed on top of the saw blade. Generally speaking, larger mesh size diamond can be used for cutting softer materials while smaller mesh size diamond is utilized for cutting harder materials. However, there are lots of interrelated things to consider and these general guidelines may 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, is a way of measuring the amount of diamond contained in a segment based upon volume. A typical reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is usually 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. Enhancing the diamond concentration by providing more cutting points can certainly make the bond act harder as well as increasing diamond tool life. Optimum performance can be accomplished if the diamond tool manufacturer utilizes his / her experience and analytical capabilities to balance diamond concentration as well as other factors to obtain optimum performance for the 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 usually more appropriate for stone and construction applications. The blocky shape provides greater potential to deal with fracturing, and so provides the maximum number of cutting points and minimum surface contact. It has a direct impact inside a lower horsepower necessity for the transformer core cutting machine as well as to increase the life to the tool. Lower grade diamond is less expensive and generally has more irregularly shaped and angular crystals which is more best for less severe applications.
Synthetic diamond could be grown in a number of mesh sizes to fit the required application. Mesh sizes are often in the range of 20 to 50 U.S. Mesh (840 to 297 microns) in construction applications. How big the diamond crystals, plus the concentration, determines the level of diamond which will be exposed over the cutting top 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 potential material removal rate. Larger diamond crystals and greater diamond protrusion will lead to a potentially faster material removal rate if you find enough horsepower available. For the most part, when cutting softer materials, larger diamond crystals are being used, and when cutting harder materials, smaller crystals are utilized.
The diamond mesh size in a cutting tool also directly refers to the amount of crystals per carat and the free cutting ability 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 may have 1,700 crystals per carat.
Specifying the correct mesh dimension is the position from the diamond tool manufacturer. Producing the right variety of cutting points can increase the life of the tool and minimize the device power requirements. For instance, a diamond tool manufacturer might want to work with a finer mesh size to increase the amount of cutting crystals with a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond will not be a similar, and this is especially valid for the potency of diamonds employed in construction applications. The power of the diamond to stand up to a direct impact load is normally referred to as diamond impact strength. Other diamond-related factors, such as crystal shape, size, inclusions as well as the distribution of those crystal properties, be a factor inside the impact strength as well.
Impact strength may be measured which is commonly referred to as Toughness Index (TI). In addition, crystals can also be exposed to extremely high temperatures during manufacturing and in some cases during the cutting process. Thermal Toughness Index (TTI) may be the way of measuring the capability of a diamond crystal to resist thermal cycling. Subjecting the diamond crystals to high temperature, letting them return to room temperature, and after that measuring the modification in toughness makes this measurement necessary to a diamond tool manufacturer.
The maker must select the best diamond depending on 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 be cut and Straight core cutting machine. These factors needs to be balanced by your selection of diamond grade and concentration that will supply the operator with optimum performance in a suitable cost.
Generally, a larger impact strength is needed for more demanding, harder-to-cut materials. However, always using higher impact strength diamond that may be higher priced will not always help the operator. It may not improve, and might degrade tool performance.
A diamond saw blade comprises a circular steel disk with segments containing the diamond that are connected to the outer perimeter of the blade (Figure 4). The diamonds are held in place from the segment, that is a specially formulated mixture of metal bond powders and diamond, which were pressed and heated inside a sintering press with the manufacturer. The diamond and bond are tailor-created to the actual cutting application. The exposed diamonds on the outside of your segment carry out the cutting. A diamond blade cuts in the 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 the diamond crystal. As being the blade rotates through the material, the diamonds chip away on the material being cut (Figure 6).
The perfect lifetime of a diamond starts by and large crystal that becomes exposed with the segment bond matrix. Since the blade begins to cut, a compact wear-flat develops plus a bond tail develops behind the diamond. Eventually, small microfractures develop, nevertheless the diamond remains to be cutting well. Then a diamond actually starts to macrofracture, and finally 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 the bond. The blade is constantly function as its cutting action is bought out through the next layer of diamonds which can be interspersed through the segment.
The metal bond matrix, which may be manufactured from iron, cobalt, nickel, bronze or other metals in a variety of combinations, was designed to wear away after many revolutions of the blade. Its wear rate is designed to ensure that it will wear for a price which will provide maximum retention from the diamond crystals and protrusion in the matrix so they can cut.
The diamond and bond come together and is particularly around the manufacturer to supply the most effective combination in relation to input through the cutting contractor given specific cutting requirements. Critical factors both for sides to address are definitely the bond system, material to be cut and machine parameters. The mix of diamond and bond accomplishes numerous critical functions.