The correct utilization of diamond blades is essential to providing economical solutions for that construction industry. The Concrete Sawing and Drilling Association, which happens to be devoted to the advancement and professionalism of concrete cutting operators, offers operators the equipment and skills necessary to understand and use 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. Additionally, they offer some safety and training videos and also a safety handbook in support of their effort to teach sawing and drilling operators. This post will discuss the usage of diamond tools, primarily saw blades, and supply ideas for their inexpensive use.
Diamond is well recognized as being the hardest substance recognized to man. One would feel that an operator of Core cutting machine could take advantage of the hardness characteristics of diamond to maximum advantage, i.e. the harder the better. In reality, this is 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 of the cutting tool. This post will examine the role diamond plays in cutting tools and the way an operator can use analytical ways to maximize the application of the diamond cutting tools thereby increasing productivity and maximizing the life of the tool.
Diamond crystals may be synthetically grown in numerous types of qualities, shapes and sizes. Synthetic diamond has replaced natural diamond in practically all construction applications as a result capacity to tailor-create the diamond for your specific application. Diamond is grown with smooth crystal faces in the cubo-octahedral shape as well as the color is usually from light yellow to medium yellow-green. Diamond is also grown to a specific toughness, which generally increases since 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. Generally speaking, larger mesh size diamond is utilized for cutting softer materials while smaller mesh size diamond can be used for cutting harder materials. However, there are numerous interrelated things to consider which general guidelines might not always apply.
The quantity of crystals per volume, or diamond concentration, also affects the cutting performance of the diamond tool. Diamond concentration, known as CON, is actually a measure of the amount of diamond incorporated into a segment based on volume. A standard reference point is 100 CON, which equals 72 carats per cubic inch. Diamond concentration for construction tools is normally 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. Boosting the diamond concentration by providing more cutting points will make the bond act harder while increasing diamond tool life. Optimum performance can be achieved once the diamond tool manufacturer utilizes his or her experience and analytical capabilities to balance diamond concentration along with other factors to achieve optimum performance for that cutting operator.
Diamond Shape & Size
Diamond shapes can 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 usually better suited for stone and construction applications. The blocky shape provides greater potential to deal with fracturing, and thus delivers the maximum number of cutting points and minimum surface contact. It has a direct impact inside a lower horsepower necessity for the EI core cutting machine as well as increase the life for your tool. Lower grade diamond is cheaper and customarily has more irregularly shaped and angular crystals which is more designed for less severe applications.
Synthetic diamond could be grown in a number of mesh sizes to suit the required application. Mesh sizes are usually in the plethora of 20 to 50 United states Mesh (840 to 297 microns) in construction applications. How big the diamond crystals, along with the concentration, determines the amount of diamond that might be exposed on top of the cutting surface 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 possible material removal rate. Larger diamond crystals and greater diamond protrusion will lead to a potentially faster material removal rate if you find enough horsepower available. For the most part, when cutting softer materials, larger diamond crystals are employed, and whenever cutting harder materials, smaller crystals are used.
The diamond mesh size in the cutting tool also directly concerns the volume of crystals per carat and also the free cutting ability to the diamond tool. The lesser 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 proper mesh size is the job from the diamond tool manufacturer. Producing the best quantity of cutting points can increase the life of the tool and reduce the machine power requirements. As an example, a diamond tool manufacturer might want to use a finer mesh size to improve the volume of cutting crystals on the low concentration tool which improves tool life and power requirements.
Diamond Impact Strength
All diamond is just not the identical, and this is especially true for the effectiveness of diamonds used in construction applications. The ability of your diamond to stand up to a positive change load is normally called diamond impact strength. Other diamond-related factors, including crystal shape, size, inclusions as well as the distribution of these crystal properties, be involved within the impact strength too.
Impact strength could be measured and it is typically called Toughness Index (TI). Furthermore, crystals will also be exposed to high temperatures during manufacturing and quite often during the cutting process. Thermal Toughness Index (TTI) is definitely the way of measuring the capability of a diamond crystal to resist 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 necessary to a diamond tool manufacturer.
The company must pick the right diamond based upon previous experience or input through the operator within the field. This decision relies, in part, in the tool’s design, bond properties, material to become cut and Straight core cutting machine. These factors has to be balanced by picking diamond grade and concentration that can provide you with the operator with optimum performance with a suitable cost.
Generally, a better impact strength is required for additional demanding, harder-to-cut materials. However, always using higher impact strength diamond that is more pricey is not going to always benefit the operator. It may possibly not improve, and can even degrade tool performance.
A diamond saw blade is made up 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 located in place through the segment, and that is a specially formulated mixture of metal bond powders and diamond, that were pressed and heated within a sintering press with the manufacturer. The diamond and bond are tailor-made to the actual cutting application. The exposed diamonds on the surface from the segment perform the cutting. A diamond blade cuts within a manner similar to how sand paper cuts wood. Because the blade cuts, bond tails are formed dexqpky76 trail behind each diamond (Figure 5). This bond tail provides mechanical support for your diamond crystal. As being the blade rotates throughout the material, the diamonds chip away with the material being cut (Figure 6).
The perfect lifetime of a diamond starts as a whole crystal that becomes exposed from the segment bond matrix. As being the blade starts to cut, a compact wear-flat develops as well as a bond tail develops behind the diamond. Eventually, small microfractures develop, however the diamond remains cutting well. Then this diamond starts to macrofracture, and finally crushes (Figure 7). This is actually the last stage of the diamond before it experiences a popout, where the diamond quite literally pops out of your bond. The blade is constantly function as its cutting action is bought out with the next layer of diamonds that are interspersed through the entire segment.
The metal bond matrix, which may be manufactured from iron, cobalt, nickel, bronze or any other metals in different combinations, was designed to wear away after many revolutions from the blade. Its wear rates are designed to ensure that it will wear for a price that can provide maximum retention of your diamond crystals and protrusion from your matrix to enable them to cut.
The diamond and bond come together and it is around the producer to deliver the most effective combination based upon input in the cutting contractor given specific cutting requirements. Critical factors both for sides to deal with will be the bond system, material to get cut and machine parameters. The mixture of diamond and bond accomplishes numerous critical functions.