The appropriate usage of diamond blades is critical to providing cost-effective solutions to the construction industry. The Concrete Sawing and Drilling Association, which happens to be committed to the advancement and professionalism of concrete cutting operators, offers operators the instruments and skills needed 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 learning flat sawing, wall sawing, core drilling, wire sawing and hand sawing. They also offer a number of safety and training videos in addition to a safety handbook in support with their effort to teach sawing and drilling operators. This information will discuss the application of diamond tools, primarily saw blades, and provide tips for their cost-effective use.
Diamond is well known since the hardest substance proven to man. One could assume that an operator of cut to length 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. If 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 post will examine the role diamond plays in cutting tools and exactly how an operator can use analytical solutions to maximize using the diamond cutting tools thereby increasing productivity and maximizing the lifestyle in the tool.
Diamond crystals can be synthetically grown in numerous types of qualities, shapes and sizes. Synthetic diamond has replaced natural diamond in nearly all construction applications for this reason capacity to tailor-make the diamond for your specific application. Diamond is grown with smooth crystal faces in the 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 being the crystal size decreases. The dimensions of the diamond crystals, commonly referred to as mesh size, determines the number of diamond cutting points exposed on top of any saw blade. Generally speaking, larger mesh size diamond is utilized 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 volume of crystals per volume, or diamond concentration, also affects the cutting performance of your diamond tool. Diamond concentration, typically called CON, is actually a measure of the level 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 range of 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 make the bond act harder as well as increasing diamond tool life. Optimum performance can be accomplished once the diamond tool manufacturer utilizes her or his experience and analytical capabilities to balance diamond concentration and other factors to attain optimum performance for that cutting operator.
Diamond Shape & Size
Diamond shapes may differ 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 generally better suited for stone and construction applications. The blocky shape provides greater effectiveness against fracturing, and thus supplies the maximum amount of cutting points and minimum surface contact. It has a direct impact in the lower horsepower necessity for the EI core cutting machine as well as increase the life for your tool. Lower grade diamond is less costly and usually has more irregularly shaped and angular crystals and it is more best for less severe applications.
Synthetic diamond may be grown in many different mesh sizes to put the required application. Mesh sizes are typically in all the different 20 to 50 United states Mesh (840 to 297 microns) in construction applications. The dimensions of the diamond crystals, and also the concentration, determines the amount of diamond that can be exposed higher than the cutting top of the segments around 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 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 concerns the amount of crystals per carat along with the free cutting ability to the diamond tool. Smaller 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 proper mesh dimension is the job of the diamond tool manufacturer. Producing the right amount of cutting points can increase the lifetime of the tool and minimize the equipment power requirements. As one example, a diamond tool manufacturer might want to use a finer mesh size to boost 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 strength of diamonds utilized in construction applications. The capability of a diamond to resist a positive change load is usually known as diamond impact strength. Other diamond-related factors, including crystal shape, size, inclusions along with the distribution of those crystal properties, play a role from the impact strength too.
Impact strength could be measured which is known as Toughness Index (TI). In addition, crystals may also be subjected to extremely high temperatures during manufacturing and often during the cutting process. Thermal Toughness Index (TTI) is definitely the way of measuring the capacity of any diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, allowing them to come back to room temperature, and after that measuring the modification in toughness makes this measurement useful to a diamond tool manufacturer.
The company must pick the best diamond based upon previous experience or input through the operator from the field. This decision is located, to some extent, about the tool’s design, bond properties, material to become cut and Straight core cutting machine. These factors has to be balanced by selecting diamond grade and concentration that can provide you with the operator with optimum performance with a suitable cost.
In general, a greater impact strength is needed for additional demanding, harder-to-cut materials. However, always using higher impact strength diamond which is more expensive 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 connected to the outer perimeter from the blade (Figure 4). The diamonds are kept in place from the segment, and that is a specially formulated mix of metal bond powders and diamond, that have been pressed and heated inside a sintering press through the manufacturer. The diamond and bond are tailor-created to the particular cutting application. The exposed diamonds on top of the segment do the cutting. A diamond blade cuts in the 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 for that diamond crystal. Since the blade rotates with the material, the diamonds chip away on the material being cut (Figure 6).
The best life of a diamond starts as a whole crystal that becomes exposed through the segment bond matrix. As the blade actually starts to cut, a compact wear-flat develops plus a bond tail develops behind the diamond. Eventually, small microfractures develop, but the diamond is still cutting well. Then a diamond starts to macrofracture, and eventually crushes (Figure 7). This is the last stage of any diamond before it experiences a popout, where the diamond quite literally pops out of the bond. The blade is constantly serve as its cutting action is bought out by the next layer of diamonds that are interspersed throughout the segment.
The metal bond matrix, which can be made of iron, cobalt, nickel, bronze or some other metals in several combinations, was created to wear away after many revolutions from the blade. Its wear rate is designed so it will wear at a rate that can provide maximum retention from the diamond crystals and protrusion from the matrix in order to cut.
The diamond and bond work together and is particularly approximately the maker to provide the most effective combination in relation to input from the cutting contractor given specific cutting requirements. Critical factors for sides to deal with would be the bond system, material being cut and machine parameters. The mixture of diamond and bond accomplishes a variety of critical functions.