The right consumption of diamond blades is vital to providing affordable solutions for the construction industry. The Concrete Sawing and Drilling Association, that is devoted to the advancement and professionalism of concrete cutting operators, offers operators the tools and skills required 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 lessons in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. In addition they offer a series of safety and training videos as well as a safety handbook in support of their effort to teach sawing and drilling operators. This information will discuss the use of diamond tools, primarily saw blades, and supply strategies for their inexpensive use.
Diamond is well recognized since the hardest substance known to man. One would feel that an operator of cut to length machine could utilize the hardness characteristics of diamond to maximum advantage, i.e. the harder the greater. In reality, this is simply not always true. Whether the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear so that you can maximize the performance of your cutting tool. This information will examine the role diamond plays in cutting tools and the way an operator are able to use analytical ways to maximize the usage of the diamond cutting tools thereby increasing productivity and maximizing the life in the tool.
Diamond crystals could be synthetically grown in numerous qualities, styles and sizes. Synthetic diamond has replaced natural diamond in nearly all construction applications due to this capability to tailor-make the diamond to the specific application. Diamond is grown with smooth crystal faces within a cubo-octahedral shape along with the color is normally from light yellow to medium yellow-green. Diamond is likewise grown to your specific toughness, which generally increases since the crystal size decreases. The size of the diamond crystals, commonly referred to as mesh size, determines the volume of diamond cutting points exposed at first glance of your saw blade. In general, 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 number of crystals per volume, or diamond concentration, also affects the cutting performance in the diamond tool. Diamond concentration, known as CON, is a measure of the level of diamond incorporated into a segment in relation to volume. A typical reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is usually 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. Enhancing the diamond concentration by supplying more cutting points is likely to make the bond act harder whilst increasing diamond tool life. Optimum performance can be accomplished once the diamond tool manufacturer utilizes her or his experience and analytical capabilities to balance diamond concentration and also other factors to accomplish optimum performance for your 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 effectiveness against fracturing, and consequently provides the maximum quantity of cutting points and minimum surface contact. It has a direct impact in a lower horsepower necessity for the Stack core cutting machine as well as increase the life for that tool. Lower grade diamond is cheaper and customarily has more irregularly shaped and angular crystals and is also more best for less severe applications.
Synthetic diamond could be grown in a range of mesh sizes to put the desired application. Mesh sizes are generally in all the different 20 to 50 Usa Mesh (840 to 297 microns) in construction applications. The size of the diamond crystals, along with the concentration, determines the amount of diamond that might be exposed over 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 opportunity material removal rate. Larger diamond crystals and greater diamond protrusion will lead to a potentially faster material removal rate if you have enough horsepower available. For the most part, when cutting softer materials, larger diamond crystals are employed, and whenever cutting harder materials, smaller crystals are employed.
The diamond mesh size in the cutting tool also directly pertains to the number of crystals per carat along with the free cutting capability of the diamond tool. Small 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 dimension is the task in the diamond tool manufacturer. Producing the right variety of cutting points can maximize the lifetime of the tool and reduce the appliance power requirements. As one example, a diamond tool manufacturer may choose to use a finer mesh size to improve the amount of cutting crystals with a 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 found in construction applications. The capability of the diamond to stand up to a positive change load is normally known as diamond impact strength. Other diamond-related factors, such as crystal shape, size, inclusions as well as the distribution of these crystal properties, be a factor in the impact strength as well.
Impact strength can be measured which is commonly referred to as Toughness Index (TI). Furthermore, crystals are also exposed to extremely high temperatures during manufacturing and in some cases in the cutting process. Thermal Toughness Index (TTI) will be the measure of the capability of a diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, letting them return to room temperature, then measuring the change in toughness makes this measurement necessary to a diamond tool manufacturer.
The manufacturer must pick the right diamond based upon previous experience or input in the operator in the field. This decision is based, in part, in the tool’s design, bond properties, material to be cut and Transformer core cutting machine. These factors needs to be balanced by picking diamond grade and concentration that will provide you with the operator with optimum performance with a suitable cost.
Generally, a better impact strength is essential for additional demanding, harder-to-cut materials. However, always using higher impact strength diamond that is higher priced will not always help the operator. It may possibly 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 kept in place through the segment, which is actually a specially formulated mix of metal bond powders and diamond, that were pressed and heated in a sintering press from the manufacturer. The diamond and bond are tailor-designed to the particular 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. 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. Because the blade rotates from the material, the diamonds chip away at the material being cut (Figure 6).
The optimal life of a diamond starts in general crystal that becomes exposed through the segment bond matrix. As being the blade starts to cut, a tiny wear-flat develops plus a bond tail develops behind the diamond. Eventually, small microfractures develop, but the diamond continues to be cutting well. Then a diamond begins 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 of your bond. The blade consistently act as its cutting action is taken over with the next layer of diamonds that happen to be interspersed during the entire segment.
The metal bond matrix, that may be made from iron, cobalt, nickel, bronze or any other metals in several combinations, was designed to wear away after many revolutions in the blade. Its wear rate is designed so that it will wear for a price that can provide maximum retention from the diamond crystals and protrusion through the matrix in order to cut.
The diamond and bond work together which is as much as the maker to deliver the very best combination based on input from the cutting contractor given specific cutting requirements. Critical factors both for sides to address would be the bond system, material to get cut and machine parameters. A combination of diamond and bond accomplishes a variety of critical functions.