The right utilization of diamond blades is vital to providing affordable solutions for the construction industry. The Concrete Sawing and Drilling Association, which is committed to the advancement and professionalism of concrete cutting operators, offers operators the various tools and skills essential 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 education in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. Additionally, they offer a series of safety and training videos as well as a safety handbook in support with their effort to teach sawing and drilling operators. This information will discuss the use of diamond tools, primarily saw blades, and provide strategies for their cost-effective use.
Diamond is well known since the hardest substance known to man. One would feel that an operator of Core cutting machine could take advantage of the hardness characteristics of diamond to maximum advantage, i.e. the harder the greater. In practice, this is not always true. Whether 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 short article will examine the role diamond plays in cutting tools and how an operator can make use of analytical ways to maximize using the diamond cutting tools thereby increasing productivity and maximizing the lifestyle of the tool.
Diamond crystals might be synthetically grown in a multitude of qualities, sizes and shapes. Synthetic diamond has replaced natural diamond in virtually all construction applications because of this power to tailor-have the diamond for your specific application. Diamond is grown with smooth crystal faces in a cubo-octahedral shape as well as the color is usually from light yellow to medium yellow-green. Diamond is likewise grown to a specific toughness, which generally increases since the crystal size decreases. The size of the diamond crystals, known as mesh size, determines the quantity of diamond cutting points exposed at first glance of a saw blade. Generally speaking, larger mesh size diamond can be used for cutting softer materials while smaller mesh size diamond is used for cutting harder materials. However, there are numerous interrelated factors to consider which general guidelines may well not always apply.
The number of crystals per volume, or diamond concentration, also affects the cutting performance of the diamond tool. Diamond concentration, commonly referred to as CON, is actually a measure of the amount of diamond contained in a segment dependant on volume. A common 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. Improving the diamond concentration through providing more cutting points can make the bond act harder whilst increasing diamond tool life. Optimum performance may be accomplished once the diamond tool manufacturer utilizes her or his 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 often more appropriate for stone and construction applications. The blocky shape provides greater potential to deal with fracturing, and thus offers the maximum variety of cutting points and minimum surface contact. This has a direct impact in the lower horsepower need for the Stack core cutting machine as well as maximize the life for that tool. Lower grade diamond is cheaper and generally has more irregularly shaped and angular crystals which is more designed for less severe applications.
Synthetic diamond can be grown in a variety of mesh sizes to put the desired application. Mesh sizes are typically in the plethora of 20 to 50 U.S. Mesh (840 to 297 microns) in construction applications. How big the diamond crystals, plus the concentration, determines the volume of diamond that will be exposed over the cutting top 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 will result in 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, so when cutting harder materials, smaller crystals are used.
The diamond mesh size within a cutting tool also directly relates to the quantity of crystals per carat and also the free cutting ability to the diamond tool. Smaller 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 work of your diamond tool manufacturer. Producing the right quantity of cutting points can maximize the life of the tool and reduce the machine power requirements. As an example, a diamond tool manufacturer may choose to utilize a finer mesh size to boost the quantity of cutting crystals with a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is just not a similar, and this is also true for the effectiveness of diamonds utilized in construction applications. The power of any diamond to stand up to an impact load is typically called 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 within the impact strength too.
Impact strength could be measured and is known as Toughness Index (TI). Furthermore, crystals can also be exposed to high temperatures during manufacturing and often in the cutting process. Thermal Toughness Index (TTI) will be the measure of the capability of a diamond crystal to stand up to thermal cycling. Subjecting the diamond crystals to high temperature, letting them return to room temperature, then measuring the alteration in toughness makes this measurement helpful to a diamond tool manufacturer.
The maker must pick the best diamond according to previous experience or input through the operator within the field. This decision is located, partly, about the tool’s design, bond properties, material to become cut and Silicon steel core cutting machine. These factors should be balanced by the selection of diamond grade and concentration that can give you the operator with optimum performance in a suitable cost.
In general, a greater impact strength is needed to get more demanding, harder-to-cut materials. However, always using higher impact strength diamond that may be more expensive will not likely always benefit the operator. It may not improve, and may even degrade tool performance.
A diamond saw blade is made up 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 locked in place from the segment, which is actually a specially formulated mixture of metal bond powders and diamond, which were pressed and heated within a sintering press from the manufacturer. The diamond and bond are tailor-created to the specific cutting application. The exposed diamonds at first glance from the segment do the cutting. A diamond blade cuts within a manner comparable to 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 your diamond crystal. Because the blade rotates from the material, the diamonds chip away in the material being cut (Figure 6).
The best life of a diamond starts in general crystal that becomes exposed with the segment bond matrix. Because the blade begins to cut, a tiny wear-flat develops along with a bond tail develops behind the diamond. Eventually, small microfractures develop, however the diamond continues to be cutting well. Then your diamond actually starts to macrofracture, and eventually crushes (Figure 7). This is basically the last stage of a diamond before it experiences a popout, where 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 are interspersed during the entire segment.
The metal bond matrix, which may be created from iron, cobalt, nickel, bronze or any other metals in different combinations, is designed to wear away after many revolutions in the blade. Its wear rate is designed to ensure that it will wear at a rate that can provide maximum retention of the diamond crystals and protrusion from your matrix so they can cut.
The diamond and bond come together and it is as much as the producer to supply the most effective combination dependant on input in the cutting contractor given specific cutting requirements. Critical factors for sides to handle are the bond system, material to be cut and machine parameters. A combination of diamond and bond accomplishes numerous critical functions.