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The correct use of diamond blades is critical to providing affordable solutions to the construction industry. The Concrete Sawing and Drilling Association, that is committed to the advancement and professionalism of concrete cutting operators, offers operators the instruments and skills required to understand and employ diamond blades for optimal performance. CSDA accomplishes this goal by providing 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 several safety and training videos and also a safety handbook in support of their effort to educate sawing and drilling operators. This article will discuss the use of diamond tools, primarily saw blades, and supply recommendations for their cost-effective use.
Diamond is well known because 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 reality, this is not always true. If the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear in order to maximize the performance from the cutting tool. This post will examine the role diamond plays in cutting tools and exactly how an operator are able to use analytical solutions to maximize the usage of the diamond cutting tools thereby increasing productivity and maximizing the lifestyle of the tool.
Diamond crystals could be synthetically grown in a multitude of qualities, shapes and forms. Synthetic diamond has replaced natural diamond in almost all construction applications due to this power to tailor-make the diamond for that specific application. Diamond is grown with smooth crystal faces in a cubo-octahedral shape and the color is typically from light yellow to medium yellow-green. Diamond is likewise grown to your specific toughness, which generally increases as the crystal size decreases. The actual size of the diamond crystals, commonly referred to as mesh size, determines the number of diamond cutting points exposed at first glance of a saw blade. Generally, larger mesh size diamond is used for cutting softer materials while smaller mesh size diamond is used for cutting harder materials. However, there are numerous 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 of your diamond tool. Diamond concentration, known as CON, is actually a measure of the level of diamond contained in 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 normally in all the different 15-50 CON. A 32 CON means the tool has 23 carats per cubic inch, or about 4 carats per segment. Increasing the diamond concentration by providing more cutting points can certainly make the bond act harder while increasing diamond tool life. Optimum performance is possible once the diamond tool manufacturer utilizes her or his experience and analytical capabilities to balance diamond concentration along with other factors to attain optimum performance for that 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 so offers the maximum variety of cutting points and minimum surface contact. It has a direct impact inside a lower horsepower necessity for the Stack core cutting machine as well as increase the life for your tool. Lower grade diamond is cheaper and usually 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 suit the specified application. Mesh sizes are generally in the plethora of 20 to 50 Usa Mesh (840 to 297 microns) in construction applications. How big the diamond crystals, as well as the concentration, determines the quantity of diamond that will be exposed on top of the cutting top 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 possibility material removal rate. Larger diamond crystals and greater diamond protrusion will lead to a potentially faster material removal rate when there is enough horsepower available. As a general rule, when cutting softer materials, larger diamond crystals are being used, and whenever cutting harder materials, smaller crystals are being used.
The diamond mesh size inside a cutting tool also directly concerns the amount of crystals per carat and the free cutting ability to 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 will have 1,700 crystals per carat.
Specifying the appropriate mesh dimension is the job of your diamond tool manufacturer. Producing the proper number of cutting points can maximize the lifetime of the tool and reduce the device power requirements. As an example, a diamond tool manufacturer might want to make use of a finer mesh size to enhance the amount of cutting crystals on the low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond will not be the same, and this is also true for the effectiveness of diamonds employed in construction applications. The capability of a diamond to withstand a positive change load is usually referred to as diamond impact strength. Other diamond-related factors, including crystal shape, size, inclusions and also the distribution of the crystal properties, are involved in the impact strength also.
Impact strength might be measured which is known as Toughness Index (TI). In addition, crystals are also subjected to quite high temperatures during manufacturing and quite often throughout the cutting process. Thermal Toughness Index (TTI) will be the way of measuring the ability of a diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, letting them return to room temperature, after which measuring the alteration in toughness makes this measurement necessary to a diamond tool manufacturer.
The maker must select the best diamond based on previous experience or input from the operator within the field. This decision relies, partly, on the tool’s design, bond properties, material to be cut and Silicon steel core cutting machine. These factors needs to be balanced by the selection of diamond grade and concentration that may provide you with the operator with optimum performance at a suitable cost.
Generally, an increased impact strength is required for further demanding, harder-to-cut materials. However, always using higher impact strength diamond that is certainly more pricey will not always benefit the operator. It may possibly not improve, and may even 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 in the blade (Figure 4). The diamonds are locked in place by the segment, that is a specially formulated blend of metal bond powders and diamond, which have been pressed and heated within a sintering press through the manufacturer. The diamond and bond are tailor-designed to the specific cutting application. The exposed diamonds on the surface from the segment do the cutting. A diamond blade cuts in a manner much like how sand paper cuts wood. As the blade cuts, bond tails are formed dexqpky76 trail behind each diamond (Figure 5). This bond tail provides mechanical support for the diamond crystal. As the blade rotates through the material, the diamonds chip away on the material being cut (Figure 6).
The optimal life of a diamond starts in general crystal that becomes exposed from the segment bond matrix. Because the blade starts to cut, a compact wear-flat develops and a bond tail develops behind the diamond. Eventually, small microfractures develop, nevertheless the diamond continues to be cutting well. Then your diamond begins to macrofracture, and eventually crushes (Figure 7). This is actually the last stage of your diamond before it experiences a popout, where diamond quite literally pops out from the bond. The blade will continue to act as its cutting action is taken over from the next layer of diamonds which can be interspersed through the segment.
The metal bond matrix, which may be created from iron, cobalt, nickel, bronze or another metals in different combinations, was designed to wear away after many revolutions of your blade. Its wear rates are designed so it will wear for a price which will provide maximum retention of your diamond crystals and protrusion from your matrix in order to cut.
The diamond and bond work together which is approximately the producer to deliver the best combination based upon input from the cutting contractor given specific cutting requirements. Critical factors for both sides to manage are definitely the bond system, material being cut and machine parameters. The combination of diamond and bond accomplishes a number of critical functions.