The correct usage of diamond blades is crucial to providing cost effective solutions for that construction industry. The Concrete Sawing and Drilling Association, that is committed to the advancement and professionalism of concrete cutting operators, offers operators the various tools and skills essential to understand and make use of diamond blades for optimal performance. CSDA accomplishes this goal by giving introductory and advanced training programs for operators with hands-on education in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. Additionally, they offer a series of safety and training videos together with a safety handbook in support in their effort to teach sawing and drilling operators. This post will discuss the usage of diamond tools, primarily saw blades, and supply tips for their inexpensive use.
Diamond is well recognized as the hardest substance known to man. One could think that an operator of cut to length machine could utilize the hardness characteristics of diamond to maximum advantage, i.e. the harder the more effective. In reality, this may not be always true. Whether or not 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 information will examine the role diamond plays in cutting tools and exactly how an operator can make use of analytical methods to maximize the use of the diamond cutting tools thereby increasing productivity and maximizing the life of your tool.
Diamond crystals could 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 ability to tailor-make your diamond for your specific application. Diamond is grown with smooth crystal faces within a cubo-octahedral shape as well as the color is typically from light yellow to medium yellow-green. Diamond is also grown to some specific toughness, which generally increases as the crystal size decreases. The actual size of the diamond crystals, known as mesh size, determines the amount of diamond cutting points exposed on top of a saw blade. In general, larger mesh size diamond is used for cutting softer materials while smaller mesh size diamond is utilized for cutting harder materials. However, there are lots of interrelated things to consider and they general guidelines might not exactly always apply.
The amount of crystals per volume, or diamond concentration, also affects the cutting performance of the diamond tool. Diamond concentration, typically called CON, is really a way of measuring the amount of diamond incorporated into 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 normally 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. Boosting the diamond concentration through providing more cutting points is likely to make the bond act harder whilst increasing diamond tool life. Optimum performance can be accomplished when the diamond tool manufacturer utilizes his or her 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 generally more appropriate for stone and construction applications. The blocky shape provides greater resistance to fracturing, and therefore delivers the maximum variety of cutting points and minimum surface contact. This has a direct impact within a lower horsepower requirement for the EI core cutting machine and also to increase the life for your tool. Lower grade diamond is less costly and customarily has more irregularly shaped and angular crystals and is more suitable for less severe applications.
Synthetic diamond can be grown in many different mesh sizes to put the required application. Mesh sizes are typically in the plethora of 20 to 50 U.S. Mesh (840 to 297 microns) in construction applications. The dimensions of the diamond crystals, as well as the concentration, determines the quantity of diamond that might be exposed over 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 and every crystal, and subsequently, the potential material removal rate. Larger diamond crystals and greater diamond protrusion can lead to a potentially faster material removal rate if you have enough horsepower available. Typically, when cutting softer materials, larger diamond crystals are utilized, so when cutting harder materials, smaller crystals are being used.
The diamond mesh size in the cutting tool also directly pertains to the number of crystals per carat and also 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 can have 1,700 crystals per carat.
Specifying the correct mesh size is the work from the diamond tool manufacturer. Producing the correct number of cutting points can increase the lifetime of the tool and reduce the appliance power requirements. As an example, a diamond tool manufacturer may choose to make use of a finer mesh size to increase the number of cutting crystals on a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond will not be the identical, and this is especially valid for the potency of diamonds employed in construction applications. The ability of any diamond to stand up to a direct impact load is normally known as diamond impact strength. Other diamond-related factors, like crystal shape, size, inclusions and the distribution of such crystal properties, be involved within the impact strength at the same time.
Impact strength can be measured and it is known as Toughness Index (TI). In addition, crystals will also be put through high temperatures during manufacturing and quite often through the cutting process. Thermal Toughness Index (TTI) may be the way of measuring the capacity of your diamond crystal to stand up to thermal cycling. Subjecting the diamond crystals to high temperature, allowing them to come back to room temperature, then measuring the alteration in toughness makes this measurement helpful to a diamond tool manufacturer.
The company must pick the best diamond according to previous experience or input from your operator in the field. This decision is situated, partly, on the tool’s design, bond properties, material to become cut and Straight core cutting machine. These factors should be balanced by selecting diamond grade and concentration which will supply the operator with optimum performance at a suitable cost.
In general, a better impact strength is essential for additional demanding, harder-to-cut materials. However, always using higher impact strength diamond which is more costly will not likely always benefit the operator. It may 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 of your blade (Figure 4). The diamonds are locked in place with the segment, that is a specially formulated mixture of metal bond powders and diamond, which were pressed and heated in the sintering press from the manufacturer. The diamond and bond are tailor-designed to the actual cutting application. The exposed diamonds on the surface of the segment do the cutting. A diamond blade cuts within 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 to the diamond crystal. As being the blade rotates throughout the material, the diamonds chip away with the material being cut (Figure 6).
The best lifetime of a diamond starts in general crystal that becomes exposed throughout the segment bond matrix. As being the blade starts to cut, a compact wear-flat develops and a bond tail develops behind the diamond. Eventually, small microfractures develop, but the diamond is still cutting well. Then your diamond actually starts to macrofracture, and in the end crushes (Figure 7). This is actually the last stage of any diamond before it experiences a popout, where diamond quite literally pops out of the bond. The blade consistently work as its cutting action is taken over through the next layer of diamonds that are interspersed through the segment.
The metal bond matrix, which is often manufactured from iron, cobalt, nickel, bronze or other metals in various combinations, was created to wear away after many revolutions of the blade. Its wear rate is designed to ensure that it will wear for a price that can provide maximum retention of the diamond crystals and protrusion through the matrix in order to cut.
The diamond and bond come together which is around the producer to offer the very best combination dependant on input from the cutting contractor given specific cutting requirements. Critical factors both for sides to address are definitely the bond system, material being cut and machine parameters. A combination of diamond and bond accomplishes a variety of critical functions.