The right utilization of diamond blades is vital to providing affordable solutions for the construction industry. The Concrete Sawing and Drilling Association, that is devoted to the advancement and professionalism of concrete cutting operators, offers operators the equipment and skills required to understand and employ diamond blades for optimal performance. CSDA accomplishes this goal by offering introductory and advanced training programs for operators with hands-on learning flat sawing, wall sawing, core drilling, wire sawing and hand sawing. In addition they offer some safety and training videos as well as a safety handbook in support in their effort to coach sawing and drilling operators. This information will discuss the application of diamond tools, primarily saw blades, and offer ideas for their inexpensive use.
Diamond is well recognized since the hardest substance seen to man. One could feel 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 simply not always true. Whether the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear in order to maximize the performance in the cutting tool. This short article will examine the role diamond plays in cutting tools and exactly how an operator may use analytical solutions to maximize the usage of the diamond cutting tools thereby increasing productivity and maximizing the life span of the tool.
Diamond crystals might be synthetically grown in a wide variety 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 to the specific application. Diamond is grown with smooth crystal faces in a cubo-octahedral shape and also the color is usually from light yellow to medium yellow-green. Diamond is additionally grown to a specific toughness, which generally increases as the crystal size decreases. How big the diamond crystals, typically called mesh size, determines the amount of diamond cutting points exposed on top of the saw blade. On the whole, larger mesh size diamond can be used for cutting softer materials while smaller mesh size diamond can be used for cutting harder materials. However, there are many interrelated things to consider and they general guidelines might not exactly always apply.
The volume of crystals per volume, or diamond concentration, also affects the cutting performance of your diamond tool. Diamond concentration, commonly referred to as CON, is really a way of measuring the amount of diamond found in a segment in relation to volume. A common reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is typically 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. Boosting the diamond concentration by supplying more cutting points is likely to make the bond act harder while increasing diamond tool life. Optimum performance may be accomplished as soon as the diamond tool manufacturer utilizes her or his experience and analytical capabilities to balance diamond concentration and other factors to attain optimum performance to 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 so delivers the maximum amount of cutting points and minimum surface contact. This has a direct impact within a lower horsepower need for the transformer core cutting machine and also to increase the life for the tool. Lower grade diamond is less costly and customarily has more irregularly shaped and angular crystals and is also more designed for less severe applications.
Synthetic diamond can be grown in a number of mesh sizes to put the desired application. Mesh sizes are generally 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 quantity of diamond that will be exposed above the cutting surface of the segments about 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 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 inside a cutting tool also directly relates to the amount of crystals per carat and the free cutting capability of 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 could have 1,700 crystals per carat.
Specifying the right mesh dimensions are the position of your diamond tool manufacturer. Producing the correct number of cutting points can increase the life of the tool and reduce the equipment power requirements. As one example, a diamond tool manufacturer might want to work with a finer mesh size to enhance 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 exactly the same, and this is also true for the effectiveness of diamonds employed in construction applications. The power of the diamond to withstand an impact load is generally called diamond impact strength. Other diamond-related factors, like crystal shape, size, inclusions and also the distribution of such crystal properties, are involved inside the impact strength as well.
Impact strength might be measured and is also typically called Toughness Index (TI). Moreover, crystals are also subjected to high temperatures during manufacturing and in some cases in the cutting process. Thermal Toughness Index (TTI) is definitely the way of measuring the power of your diamond crystal to resist thermal cycling. Subjecting the diamond crystals to high temperature, permitting them to go back to room temperature, and then measuring the change in toughness makes this measurement helpful to a diamond tool manufacturer.
The manufacturer must pick the right diamond based upon previous experience or input from the operator within the field. This decision is based, to some extent, on the tool’s design, bond properties, material being cut and Silicon steel core cutting machine. These factors should be balanced by selecting diamond grade and concentration that may supply the operator with optimum performance at a suitable cost.
Generally speaking, a larger impact strength is required to get more demanding, harder-to-cut materials. However, always using higher impact strength diamond that may be more pricey will not likely always benefit the operator. It might not improve, and might degrade tool performance.
A diamond saw blade is composed 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, which is actually a specially formulated blend of metal bond powders and diamond, which have been pressed and heated in the sintering press by the manufacturer. The diamond and bond are tailor-created to the particular cutting application. The exposed diamonds at first glance of the segment perform the cutting. A diamond blade cuts in a manner comparable to 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 being the blade rotates through the material, the diamonds chip away with the material being cut (Figure 6).
The ideal life of a diamond starts overall crystal that becomes exposed throughout the segment bond matrix. Because the blade starts to cut, a small wear-flat develops plus a bond tail develops behind the diamond. Eventually, small microfractures develop, but the diamond continues to be cutting well. Then the diamond starts to macrofracture, and in the end crushes (Figure 7). Here is the last stage of your diamond before it experiences a popout, in which the diamond quite literally pops out of your bond. The blade consistently serve as its cutting action is bought out by the next layer of diamonds that happen to be interspersed through the segment.
The metal bond matrix, which may be made of iron, cobalt, nickel, bronze or other metals in different combinations, is designed to wear away after many revolutions of the blade. Its wear rates are designed so that it will wear at a rate that will provide maximum retention of your diamond crystals and protrusion from the matrix to enable them to cut.
The diamond and bond work together which is as much as the maker to supply the very best combination dependant on input from your cutting contractor given specific cutting requirements. Critical factors both for sides to deal with will be the bond system, material being cut and machine parameters. The combination of diamond and bond accomplishes several critical functions.