The proper utilization of diamond blades is critical to providing economical solutions for the construction industry. The Concrete Sawing and Drilling Association, which happens to be focused on the advancement and professionalism of concrete cutting operators, offers operators the tools and skills essential 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 training in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. They also offer several safety and training videos in addition to a safety handbook in support of their effort to coach sawing and drilling operators. This short article will discuss the use of diamond tools, primarily saw blades, and give recommendations for their inexpensive use.
Diamond is well known because the hardest substance proven to man. One could believe that an operator of cut to length machine could use the hardness characteristics of diamond to maximum advantage, i.e. the harder the better. In practice, this is simply not always true. Whether or not the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear as a way to increase the performance in the cutting tool. This post will examine the role diamond plays in cutting tools and just how an operator can use analytical methods to maximize the application of the diamond cutting tools thereby increasing productivity and maximizing the lifespan in the tool.
Diamond crystals might be synthetically grown in a wide variety of qualities, shapes and sizes. Synthetic diamond has replaced natural diamond in virtually all construction applications for this reason ability to tailor-have the diamond for that specific application. Diamond is grown with smooth crystal faces in the cubo-octahedral shape and also the color is typically from light yellow to medium yellow-green. Diamond is additionally grown to a specific toughness, which generally increases since the crystal size decreases. How big the diamond crystals, known as mesh size, determines the number of diamond cutting points exposed on top of your saw blade. Generally speaking, 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 lots of interrelated things to consider and those 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, typically called CON, is actually a way of measuring the volume of diamond within a segment dependant on volume. A frequent reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is typically 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. Improving the diamond concentration through providing more cutting points can certainly make the bond act harder as well as increasing diamond tool life. Optimum performance may be accomplished as soon as the diamond tool manufacturer utilizes their experience and analytical capabilities to balance diamond concentration and also other factors to accomplish 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 consequently supplies the maximum quantity of cutting points and minimum surface contact. It has a direct impact within a lower horsepower requirement for the Stack core cutting machine and also to maximize the life to the tool. Lower grade diamond is cheaper and customarily 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 suit the specified application. Mesh sizes are generally in the range of 20 to 50 Usa Mesh (840 to 297 microns) in construction applications. The actual size of the diamond crystals, along with the concentration, determines the volume of diamond that will be exposed over the cutting top 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 potential 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. As a general rule, when cutting softer materials, larger diamond crystals are being used, so when cutting harder materials, smaller crystals are being used.
The diamond mesh size inside a cutting tool also directly pertains to the number of crystals per carat along with the free cutting capability of 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 could have 1,700 crystals per carat.
Specifying the right mesh size is the task from the diamond tool manufacturer. Producing the right quantity of cutting points can maximize the lifetime of the tool and minimize the appliance power requirements. For instance, a diamond tool manufacturer may choose to make use of a finer mesh size to improve the number of cutting crystals over a low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is not really exactly the same, and this is also true for the effectiveness of diamonds utilized in construction applications. The power of the diamond to stand up to an impact load is normally called diamond impact strength. Other diamond-related factors, like crystal shape, size, inclusions along with the distribution of these crystal properties, play a role inside the impact strength too.
Impact strength could be measured which is known as Toughness Index (TI). Moreover, crystals can also be subjected to very high temperatures during manufacturing and sometimes through the cutting process. Thermal Toughness Index (TTI) will be the measure of the ability of your diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, letting them go back to room temperature, then measuring the change in toughness makes this measurement beneficial to a diamond tool manufacturer.
The maker must pick the right diamond according to previous experience or input through the operator in the field. This decision is located, partly, about the tool’s design, bond properties, material being cut and Straight core cutting machine. These factors must be balanced by selecting diamond grade and concentration which will give you the operator with optimum performance in a suitable cost.
Generally speaking, a better impact strength is needed to get more demanding, harder-to-cut materials. However, always using higher impact strength diamond that is certainly more pricey will never always benefit the operator. It may not improve, and might 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 of the blade (Figure 4). The diamonds are locked in place with the segment, which is actually a specially formulated mixture of metal bond powders and diamond, that have been pressed and heated in the sintering press from the manufacturer. The diamond and bond are tailor-created to the specific cutting application. The exposed diamonds on the surface in the segment do the cutting. A diamond blade cuts in 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 for your diamond crystal. Because the blade rotates through the material, the diamonds chip away with the material being cut (Figure 6).
The optimal lifetime of a diamond starts by and large crystal that becomes exposed from the segment bond matrix. Since the blade 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 your diamond begins to macrofracture, and finally crushes (Figure 7). This is the last stage of any diamond before it experiences a popout, the location where the diamond quite literally pops out of the bond. The blade will continue to work as its cutting action is bought out from the next layer of diamonds that are interspersed through the entire segment.
The metal bond matrix, which is often made of iron, cobalt, nickel, bronze or other metals in various combinations, is made to wear away after many revolutions from the blade. Its wear rate is designed so it will wear at a rate that may provide maximum retention from the diamond crystals and protrusion through the matrix in order to cut.
The diamond and bond interact with each other in fact it is as much as the company to deliver the ideal combination based upon input through the cutting contractor given specific cutting requirements. Critical factors both for sides to handle would be the bond system, material to be cut and machine parameters. The combination of diamond and bond accomplishes numerous critical functions.