The right utilization of diamond blades is essential to providing affordable solutions for your 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 instruments and skills required to understand and use diamond blades for optimal performance. CSDA accomplishes this goal by giving introductory and advanced training programs for operators with hands-on training in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. Additionally, they offer a number of safety and training videos together with a safety handbook in support of their effort to coach sawing and drilling operators. This information will discuss using diamond tools, primarily saw blades, and offer strategies for their inexpensive use.
Diamond is well known as the hardest substance proven 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 better. In practice, this may not be always true. Regardless of if the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear so that you can maximize the performance in the cutting tool. This article will examine the role diamond plays in cutting tools and just how an operator can make use of analytical solutions to maximize the use of the diamond cutting tools thereby increasing productivity and maximizing the life in the tool.
Diamond crystals can be synthetically grown in numerous types of qualities, shapes and forms. Synthetic diamond has replaced natural diamond in virtually all construction applications as a result capacity to tailor-have the diamond for that specific application. Diamond is grown with smooth crystal faces in a cubo-octahedral shape as well as the color is normally from light yellow to medium yellow-green. Diamond is also 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 amount of diamond cutting points exposed at first glance of a saw blade. Generally, larger mesh size diamond is utilized for cutting softer materials while smaller mesh size diamond is commonly used for cutting harder materials. However, there are several interrelated factors to consider and they general guidelines may not always apply.
The volume of crystals per volume, or diamond concentration, also affects the cutting performance in the diamond tool. Diamond concentration, commonly referred to as CON, can be a measure of the quantity 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 generally in the plethora of 15-50 CON. A 32 CON would mean that 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 is possible when the diamond tool manufacturer utilizes their experience and analytical capabilities to balance diamond concentration and other factors to achieve 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 generally more appropriate for stone and construction applications. The blocky shape provides greater resistance to fracturing, and consequently supplies the maximum number of cutting points and minimum surface contact. It has a direct impact in the lower horsepower need for the Stack core cutting machine and also to maximize the life to the tool. Lower grade diamond is less expensive and usually has more irregularly shaped and angular crystals and it is more designed for less severe applications.
Synthetic diamond could be grown in a number of mesh sizes to put the preferred application. Mesh sizes are often in all the different 20 to 50 United states Mesh (840 to 297 microns) in construction applications. The actual size of the diamond crystals, and also the concentration, determines the volume of diamond that will be exposed higher than the cutting top of the segments about the blade. The exposure, or height, of diamond protrusion (Figure 3) influences the depth of cut of every 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. Typically, when cutting softer materials, larger diamond crystals are employed, so when cutting harder materials, smaller crystals are used.
The diamond mesh size inside a cutting tool also directly pertains to the amount of crystals per carat and also 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 will have 1,700 crystals per carat.
Specifying the proper mesh dimensions are the work of the diamond tool manufacturer. Producing the right quantity of cutting points can increase the life of the tool and minimize the device power requirements. As one example, a diamond tool manufacturer may choose to use a finer mesh size to improve the number of cutting crystals on the low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is not the same, and this is especially valid for the effectiveness of diamonds found in construction applications. The ability of the diamond to stand up to a direct impact load is generally called diamond impact strength. Other diamond-related factors, for example crystal shape, size, inclusions and also the distribution of the crystal properties, play a role inside the impact strength as well.
Impact strength may be measured and it 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 through the cutting process. Thermal Toughness Index (TTI) may be the way of measuring the ability of a diamond crystal to resist thermal cycling. Subjecting the diamond crystals to high temperature, allowing them to return to room temperature, and then measuring the modification in toughness makes this measurement beneficial to a diamond tool manufacturer.
The maker must select the right diamond based upon previous experience or input in the operator from the field. This decision is based, partly, around the tool’s design, bond properties, material being cut and Transformer core cutting machine. These factors must be balanced by the selection of diamond grade and concentration that will give you the operator with optimum performance at the suitable cost.
Generally speaking, a better impact strength is necessary for additional demanding, harder-to-cut materials. However, always using higher impact strength diamond that is more expensive will not always help the operator. It may not improve, and may even degrade tool performance.
A diamond saw blade comprises a circular steel disk with segments containing the diamond that are affixed to the outer perimeter from the blade (Figure 4). The diamonds are kept in place through the segment, and that is a specially formulated blend of metal bond powders and diamond, which were pressed and heated in a sintering press from the manufacturer. The diamond and bond are tailor-intended to the actual cutting application. The exposed diamonds at first glance of your segment do the cutting. A diamond blade cuts inside a manner just like 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. Because the blade rotates through the material, the diamonds chip away at the material being cut (Figure 6).
The ideal life of a diamond starts overall crystal that becomes exposed through the segment bond matrix. Since the blade starts to cut, a small wear-flat develops as well as a bond tail develops behind the diamond. Eventually, small microfractures develop, nevertheless the diamond remains to be cutting well. Then the diamond begins to macrofracture, and finally crushes (Figure 7). Here is the last stage of a diamond before it experiences a popout, where diamond quite literally pops out from the bond. The blade continues to function as its cutting action is taken over with the next layer of diamonds which are interspersed throughout the segment.
The metal bond matrix, which can be manufactured from iron, cobalt, nickel, bronze or other metals in different combinations, is made to wear away after many revolutions in the blade. Its wear rates are designed to ensure that it will wear for a price that will provide maximum retention of the diamond crystals and protrusion in the matrix in order to cut.
The diamond and bond interact and is particularly as much as the maker to deliver the very best combination based on input in the cutting contractor given specific cutting requirements. Critical factors for both sides to deal with are definitely the bond system, material to get cut and machine parameters. A combination of diamond and bond accomplishes several critical functions.