The correct utilization of diamond blades is essential to providing affordable solutions to 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 necessary 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 learning flat sawing, wall sawing, core drilling, wire sawing and hand sawing. They also offer a series of safety and training videos together with a safety handbook in support of their effort to coach sawing and drilling operators. This short article will discuss using diamond tools, primarily saw blades, and provide ideas for their inexpensive use.
Diamond is well known as the hardest substance recognized to man. One would think that an operator of Core cutting machine could utilize the hardness characteristics of diamond to maximum advantage, i.e. the harder the better. In reality, this is not always true. Whether or not the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear to be able to increase the performance of the cutting tool. This article will examine the role diamond plays in cutting tools and the way an operator may use analytical techniques to maximize the application of the diamond cutting tools thereby increasing productivity and maximizing the life span of the tool.
Diamond crystals could be synthetically grown in numerous qualities, shapes and sizes. Synthetic diamond has replaced natural diamond in practically all construction applications due to this power to tailor-have the diamond for the specific application. Diamond is grown with smooth crystal faces in the cubo-octahedral shape and also the color is typically from light yellow to medium yellow-green. Diamond is likewise grown to your specific toughness, which generally increases since the crystal size decreases. The dimensions of the diamond crystals, typically called mesh size, determines the quantity of diamond cutting points exposed at first glance of any saw blade. Generally speaking, larger mesh size diamond is commonly used for cutting softer materials while smaller mesh size diamond is commonly used for cutting harder materials. However, there are lots of interrelated considerations and they general guidelines may not always apply.
The amount of crystals per volume, or diamond concentration, also affects the cutting performance from the diamond tool. Diamond concentration, typically called CON, is actually a measure of the amount of diamond found in a segment dependant on volume. A typical 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. Increasing the diamond concentration by offering more cutting points is likely to make the bond act harder while also 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 along with other factors to achieve 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 resistance to fracturing, and therefore offers the maximum number of cutting points and minimum surface contact. This has a direct impact inside a lower horsepower requirement of the transformer core cutting machine as well as to maximize the life for the tool. Lower grade diamond is less costly and usually has more irregularly shaped and angular crystals and is also more suitable for less severe applications.
Synthetic diamond might be grown in a number of mesh sizes to suit the desired application. Mesh sizes are usually in all the different 20 to 50 Usa Mesh (840 to 297 microns) in construction applications. How big the diamond crystals, as well as the concentration, determines the amount of diamond which will be exposed on top of the cutting surface 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 opportunity material removal rate. Larger diamond crystals and greater diamond protrusion will lead to a potentially faster material removal rate should there be enough horsepower available. Typically, when cutting softer materials, larger diamond crystals are being used, and once cutting harder materials, smaller crystals are being used.
The diamond mesh size inside a cutting tool also directly relates to the quantity of crystals per carat and also the free cutting capability of the diamond tool. The 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 dimension is the job of the diamond tool manufacturer. Producing the right quantity of cutting points can increase the lifetime of the tool and reduce the machine power requirements. As an example, a diamond tool manufacturer may choose to use a finer mesh size to improve the volume of cutting crystals on the 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 potency of diamonds used in construction applications. The capability of any diamond to resist an effect load is usually referred to as diamond impact strength. Other diamond-related factors, including crystal shape, size, inclusions as well as the distribution of the crystal properties, be involved in the impact strength at the same time.
Impact strength could be measured and is also commonly referred to as Toughness Index (TI). Furthermore, crystals can also be exposed to high temperatures during manufacturing and quite often in the cutting process. Thermal Toughness Index (TTI) may be the way of measuring the ability of your diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, letting them return to room temperature, after which measuring the change in toughness makes this measurement helpful to a diamond tool manufacturer.
The maker must select the best diamond depending on previous experience or input through the operator in the field. This decision is located, in part, around the tool’s design, bond properties, material being cut and Silicon steel core cutting machine. These factors has to be balanced by selecting diamond grade and concentration that may provide you with the operator with optimum performance at a suitable cost.
On the whole, a better impact strength is necessary for further demanding, harder-to-cut materials. However, always using higher impact strength diamond which is more pricey will never always benefit the operator. It might not improve, and can even degrade tool performance.
A diamond saw blade comprises a circular steel disk with segments containing the diamond that are connected to the outer perimeter from the blade (Figure 4). The diamonds are held in place through the segment, that is a specially formulated combination of metal bond powders and diamond, that have been pressed and heated within a sintering press from the manufacturer. The diamond and bond are tailor-created to the precise cutting application. The exposed diamonds on the surface of your segment do the cutting. A diamond blade cuts in a 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 to the diamond crystal. Because the blade rotates throughout the material, the diamonds chip away with the material being cut (Figure 6).
The optimal life of a diamond starts overall crystal that becomes exposed through the segment bond matrix. As the blade begins to cut, a little wear-flat develops plus a bond tail develops behind the diamond. Eventually, small microfractures develop, but the diamond continues to be cutting well. Then this diamond starts to macrofracture, and ultimately crushes (Figure 7). This is 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 act as its cutting action is bought out through the next layer of diamonds which can be interspersed during the entire segment.
The metal bond matrix, which is often manufactured from iron, cobalt, nickel, bronze or any other metals in different combinations, was created to wear away after many revolutions of your blade. Its wear rates are designed so it will wear for a price that may provide maximum retention of your diamond crystals and protrusion from the matrix so they can cut.
The diamond and bond work together which is approximately the manufacturer to deliver the very best combination in relation to input from your cutting contractor given specific cutting requirements. Critical factors for sides to address would be the bond system, material being cut and machine parameters. The mix of diamond and bond accomplishes numerous critical functions.