The right usage of diamond blades is essential to providing economical solutions to the construction industry. The Concrete Sawing and Drilling Association, which happens to be dedicated to the advancement and professionalism of concrete cutting operators, offers operators the instruments and skills needed to understand and employ diamond blades for optimal performance. CSDA accomplishes this goal through providing introductory and advanced training programs for operators with hands-on lessons in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. Additionally they offer a number of safety and training videos and also a safety handbook in support of their effort to educate sawing and drilling operators. This post will discuss using diamond tools, primarily saw blades, and provide ideas for their inexpensive use.
Diamond is well recognized since the hardest substance recognized to man. One could think that an operator of cut to length machine could use the hardness characteristics of diamond to maximum advantage, i.e. the harder the higher. In practice, this is not always true. If the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear so that you can increase the performance of your cutting tool. This information will examine the role diamond plays in cutting tools and exactly how an operator can make use of analytical ways to maximize the usage of the diamond cutting tools thereby increasing productivity and maximizing the lifespan from 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 for this reason ability to tailor-make your diamond for the specific application. Diamond is grown with smooth crystal faces in a cubo-octahedral shape and also the color is normally from light yellow to medium yellow-green. Diamond is additionally grown to some specific toughness, which generally increases as being the crystal size decreases. The size of the diamond crystals, known as mesh size, determines the quantity of diamond cutting points exposed on top of your saw blade. On the whole, larger mesh size diamond is used for cutting softer materials while smaller mesh size diamond can be used for cutting harder materials. However, there are numerous interrelated considerations and these 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, known as CON, is actually a measure of the level of diamond within a segment based upon volume. A standard reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is usually 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. Enhancing the diamond concentration by offering more cutting points will make the bond act harder while also increasing diamond tool life. Optimum performance is possible once the diamond tool manufacturer utilizes his / her experience and analytical capabilities to balance diamond concentration and other factors to obtain 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 typically better suited for stone and construction applications. The blocky shape provides greater effectiveness against fracturing, and thus delivers the maximum amount of cutting points and minimum surface contact. This has a direct impact in the lower horsepower necessity for the transformer core cutting machine and to maximize the life for the tool. Lower grade diamond is less expensive and generally has more irregularly shaped and angular crystals and is more best for less severe applications.
Synthetic diamond might be grown in many different mesh sizes to put the required application. Mesh sizes are often in the plethora of 20 to 50 United states Mesh (840 to 297 microns) in construction applications. The size of the diamond crystals, along with the concentration, determines the amount of diamond that will be exposed over 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 result in a potentially faster material removal rate if you find enough horsepower available. For the most part, when cutting softer materials, larger diamond crystals are being used, and whenever cutting harder materials, smaller crystals are used.
The diamond mesh size in the cutting tool also directly pertains to the amount of crystals per carat as well as the free cutting ability of the diamond tool. Small 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 can have 1,700 crystals per carat.
Specifying the correct mesh dimensions are the task from the diamond tool manufacturer. Producing the proper number of cutting points can increase the lifetime of the tool and minimize the machine power requirements. For example, a diamond tool manufacturer may choose to utilize a finer mesh size to improve the volume of cutting crystals over a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is just not a similar, and this is especially valid for the effectiveness of diamonds employed in construction applications. The capability of any diamond to stand up to a positive change load is typically referred to as diamond impact strength. Other diamond-related factors, like crystal shape, size, inclusions along with the distribution of such crystal properties, play a role in the impact strength as well.
Impact strength could be measured and is also typically called Toughness Index (TI). Furthermore, crystals are also put through quite high temperatures during manufacturing and sometimes during the cutting process. Thermal Toughness Index (TTI) is the way of measuring the capability of a diamond crystal to resist thermal cycling. Subjecting the diamond crystals to high temperature, letting them return to room temperature, and then measuring the alteration in toughness makes this measurement necessary to a diamond tool manufacturer.
The producer must pick the right diamond based upon previous experience or input from your operator inside the field. This decision is located, to some extent, in the tool’s design, bond properties, material to become cut and Transformer core cutting machine. These factors needs to be balanced by selecting diamond grade and concentration which will provide the operator with optimum performance at a suitable cost.
Generally, an increased impact strength is necessary to get more demanding, harder-to-cut materials. However, always using higher impact strength diamond that may be higher priced will not likely always benefit the operator. It may not improve, and may also degrade tool performance.
A diamond saw blade is composed of a circular steel disk with segments containing the diamond that are affixed to the outer perimeter in the blade (Figure 4). The diamonds are held in place with the segment, that is a specially formulated mixture of metal bond powders and diamond, which have been pressed and heated inside a sintering press with the manufacturer. The diamond and bond are tailor-created to the specific cutting application. The exposed diamonds on top from the segment carry out the cutting. A diamond blade cuts in a manner similar 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 that diamond crystal. As the blade rotates with the material, the diamonds chip away with the material being cut (Figure 6).
The ideal lifetime of a diamond starts by and large crystal that becomes exposed throughout the segment bond matrix. As the blade starts to cut, a compact wear-flat develops along with a bond tail develops behind the diamond. Eventually, small microfractures develop, although the diamond is still cutting well. Then the diamond starts to macrofracture, and ultimately crushes (Figure 7). This is basically the last stage of a diamond before it experiences a popout, in which the diamond quite literally pops out of the bond. The blade consistently act as its cutting action is bought out through the next layer of diamonds that are interspersed during the entire segment.
The metal bond matrix, which can be made from iron, cobalt, nickel, bronze or other metals in a variety of combinations, was designed to wear away after many revolutions of the blade. Its wear rates are designed in order that it will wear at a rate which will provide maximum retention in the diamond crystals and protrusion from the matrix in order to cut.
The diamond and bond come together and it is around the manufacturer to provide the best combination in relation to input from your 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 number of critical functions.