The correct use of diamond blades is crucial to providing economical solutions for your construction industry. The Concrete Sawing and Drilling Association, which is dedicated to the advancement and professionalism of concrete cutting operators, offers operators the tools and skills necessary to understand and make use of diamond blades for optimal performance. CSDA accomplishes this goal by providing introductory and advanced training programs for operators with hands-on lessons in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. They also offer several safety and training videos as well as a safety handbook in support in their effort to educate sawing and drilling operators. This article will discuss using diamond tools, primarily saw blades, and offer strategies for their cost-effective use.
Diamond is well recognized because the hardest substance proven to man. One would believe that an operator of Core cutting machine could take advantage of the hardness characteristics of diamond to maximum advantage, i.e. the harder the better. In practice, this is simply not always true. If the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear so that you can increase the performance of your cutting tool. This article will examine the role diamond plays in cutting tools and the way an operator can use analytical methods to maximize the use of the diamond cutting tools thereby increasing productivity and maximizing the life span from the tool.
Diamond crystals might be synthetically grown in a multitude of qualities, shapes and sizes. Synthetic diamond has replaced natural diamond in virtually all construction applications for this reason capability to tailor-make the diamond to 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 is also grown to some specific toughness, which generally increases as being the crystal size decreases. How big the diamond crystals, known as mesh size, determines the volume of diamond cutting points exposed on top of your saw blade. Generally, larger mesh size diamond is utilized for cutting softer materials while smaller mesh size diamond can be used for cutting harder materials. However, there are many interrelated factors to consider and those general guidelines might not exactly always apply.
The amount of crystals per volume, or diamond concentration, also affects the cutting performance in the diamond tool. Diamond concentration, commonly referred to as CON, is actually a measure of the level of diamond contained in a segment based on volume. A common reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is usually 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. Enhancing the diamond concentration through providing more cutting points can certainly make the bond act harder as well as increasing diamond tool life. Optimum performance is possible once the diamond tool manufacturer utilizes their experience and analytical capabilities to balance diamond concentration as well as other factors to obtain optimum performance for your cutting operator.
Diamond Shape & Size
Diamond shapes can 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 typically more appropriate for stone and construction applications. The blocky shape provides greater potential to deal with fracturing, and thus supplies the maximum amount of cutting points and minimum surface contact. It has a direct impact within a lower horsepower requirement for the EI core cutting machine and also to increase the life to the tool. Lower grade diamond is less expensive and customarily has more irregularly shaped and angular crystals which is more suitable for less severe applications.
Synthetic diamond may be grown in a number of mesh sizes to match the specified application. Mesh sizes are often in the range of 20 to 50 Usa Mesh (840 to 297 microns) in construction applications. The dimensions of the diamond crystals, as well as the concentration, determines the amount of diamond that can be exposed higher than the cutting top 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 possible material removal rate. Larger diamond crystals and greater diamond protrusion can result in a potentially faster material removal rate when there is enough horsepower available. On the whole, when cutting softer materials, larger diamond crystals are utilized, and whenever cutting harder materials, smaller crystals are employed.
The diamond mesh size in a cutting tool also directly relates to the number of crystals per carat along with the free cutting ability to 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 can have 1,700 crystals per carat.
Specifying the correct mesh size is the task of the diamond tool manufacturer. Producing the proper number of cutting points can maximize the lifetime of the tool and reduce the device power requirements. As one example, a diamond tool manufacturer may choose to work with a finer mesh size to boost the quantity of cutting crystals over a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond will not be exactly the same, and this is especially valid for the strength of diamonds employed in construction applications. The power of your diamond to withstand a positive change load is generally termed as diamond impact strength. Other diamond-related factors, including crystal shape, size, inclusions as well as the distribution of those crystal properties, be a factor from the impact strength too.
Impact strength might be measured which is known as Toughness Index (TI). In addition, crystals can also be subjected to high temperatures during manufacturing and quite often during the cutting process. Thermal Toughness Index (TTI) is the way of measuring the capacity of any diamond crystal to resist thermal cycling. Subjecting the diamond crystals to high temperature, allowing them to return to room temperature, and then measuring the change in toughness makes this measurement useful to a diamond tool manufacturer.
The company must select the best diamond based on previous experience or input in the operator from the field. This decision is based, to some extent, on the tool’s design, bond properties, material to become cut and Transformer core cutting machine. These factors must be balanced by the selection of diamond grade and concentration that may provide the operator with optimum performance at a suitable cost.
Generally, a greater impact strength is necessary for further demanding, harder-to-cut materials. However, always using higher impact strength diamond that is certainly more pricey will never always help the operator. It may possibly 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 from the blade (Figure 4). The diamonds are located in place from the segment, that is a specially formulated blend of metal bond powders and diamond, that have been pressed and heated within a sintering press with the manufacturer. The diamond and bond are tailor-intended to the particular cutting application. The exposed diamonds on the outside from the segment carry out the cutting. A diamond blade cuts inside a manner comparable to 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. Since the blade rotates from the material, the diamonds chip away on the material being cut (Figure 6).
The best lifetime of a diamond starts as a whole crystal that becomes exposed with the segment bond matrix. As being the blade actually starts to cut, a compact wear-flat develops as well as a bond tail develops behind the diamond. Eventually, small microfractures develop, but the diamond is still cutting well. Then this diamond starts to macrofracture, and in the end crushes (Figure 7). This is basically the last stage of your diamond before it experiences a popout, in which the diamond quite literally pops out of the bond. The blade will continue to work as its cutting action is taken over with the next layer of diamonds that are interspersed through the segment.
The metal bond matrix, which may be made from iron, cobalt, nickel, bronze or other metals in several combinations, was created to wear away after many revolutions of your blade. Its wear rate is designed so it will wear at a rate which will provide maximum retention from the diamond crystals and protrusion through the matrix so that they can cut.
The diamond and bond work together in fact it is approximately the maker to deliver the very best combination dependant on input from your cutting contractor given specific cutting requirements. Critical factors for both sides to handle are definitely the bond system, material to be cut and machine parameters. The combination of diamond and bond accomplishes a variety of critical functions.