The appropriate usage of diamond blades is vital to providing cost effective solutions to the construction industry. The Concrete Sawing and Drilling Association, that is devoted to the advancement and professionalism of concrete cutting operators, offers operators the equipment and skills required to understand and use diamond blades for optimal performance. CSDA accomplishes this goal by providing introductory and advanced training programs for operators with hands-on education in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. In addition they offer some safety and training videos and also a safety handbook in support of their effort to teach sawing and drilling operators. This information will discuss the use of diamond tools, primarily saw blades, and give tips for their inexpensive use.
Diamond is well known because the hardest substance proven to man. One would think that an operator of Core cutting machine could take advantage of the hardness characteristics of diamond to maximum advantage, i.e. the harder the more effective. 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 maximize the performance in the cutting tool. This article will examine the role diamond plays in cutting tools and just how an operator are able to use analytical ways to maximize the use of the diamond cutting tools thereby increasing productivity and maximizing the lifestyle of your tool.
Diamond crystals could be synthetically grown in a multitude of qualities, shapes and forms. Synthetic diamond has replaced natural diamond in virtually all construction applications for this reason capability to tailor-make your diamond for your specific application. Diamond is grown with smooth crystal faces in a cubo-octahedral shape as well as the color is usually from light yellow to medium yellow-green. Diamond is likewise grown to your specific toughness, which generally increases as the crystal size decreases. The actual size of the diamond crystals, typically called mesh size, determines the number of diamond cutting points exposed on the outside of any saw blade. Generally, 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 factors to consider and they general guidelines might not exactly always apply.
The volume of crystals per volume, or diamond concentration, also affects the cutting performance from the diamond tool. Diamond concentration, typically called CON, is actually a measure of the quantity of diamond within 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 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 by supplying more cutting points can certainly make the bond act harder whilst increasing diamond tool life. Optimum performance can be accomplished 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 the 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 typically better suited for stone and construction applications. The blocky shape provides greater effectiveness against fracturing, and therefore supplies the maximum amount of cutting points and minimum surface contact. This has a direct impact inside a lower horsepower necessity for the Stack core cutting machine as well as maximize the life for the tool. Lower grade diamond is less costly and customarily has more irregularly shaped and angular crystals and is more designed for less severe applications.
Synthetic diamond could be grown in a variety of mesh sizes to fit the specified application. Mesh sizes are often in the range of 20 to 50 Usa Mesh (840 to 297 microns) in construction applications. How big the diamond crystals, plus the concentration, determines the amount of diamond that can 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 for each crystal, and subsequently, the opportunity 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 used, and once cutting harder materials, smaller crystals are being used.
The diamond mesh size within a cutting tool also directly pertains to the amount of crystals per carat along with the free cutting ability of 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 work from the diamond tool manufacturer. Producing the right quantity of cutting points can increase the lifetime of the tool and minimize the device power requirements. As an example, a diamond tool manufacturer may choose to work with 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 will not be exactly the same, and this is also true for the potency of diamonds utilized in construction applications. The power of any diamond to stand up to an impact load is typically termed as diamond impact strength. Other diamond-related factors, for example crystal shape, size, inclusions along with the distribution of the crystal properties, be involved from the impact strength as well.
Impact strength can be measured and is known as Toughness Index (TI). Furthermore, crystals may also be put through quite high temperatures during manufacturing and sometimes through the cutting process. Thermal Toughness Index (TTI) may be the measure of the ability of your diamond crystal to stand up to thermal cycling. Subjecting the diamond crystals to high temperature, letting them return to room temperature, and then measuring the modification in toughness makes this measurement beneficial to a diamond tool manufacturer.
The manufacturer must select the best diamond based upon previous experience or input from your operator in the field. This decision is situated, in part, about the tool’s design, bond properties, material to become cut and Transformer core cutting machine. These factors should be balanced by picking diamond grade and concentration that can supply the operator with optimum performance at a suitable cost.
On the whole, an increased impact strength is essential for additional demanding, harder-to-cut materials. However, always using higher impact strength diamond that may be more expensive will not likely always help the operator. It may not improve, and can even 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 locked in place by the segment, that is a specially formulated mixture of metal bond powders and diamond, that have been pressed and heated within a sintering press with the manufacturer. The diamond and bond are tailor-designed to the actual cutting application. The exposed diamonds at first glance from the segment perform cutting. A diamond blade cuts in the 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. As the blade rotates from the material, the diamonds chip away in the material being cut (Figure 6).
The optimal life of a diamond starts by and large crystal that becomes exposed throughout the segment bond matrix. Because the blade actually starts to cut, a little wear-flat develops as well as a bond tail develops behind the diamond. Eventually, small microfractures develop, nevertheless the diamond remains to be cutting well. Then your diamond actually starts to macrofracture, and ultimately crushes (Figure 7). This is actually the last stage of any diamond before it experiences a popout, where diamond quite literally pops from the bond. The blade will continue to act as its cutting action is bought out from the next layer of diamonds that happen to be interspersed throughout the segment.
The metal bond matrix, which can be manufactured from iron, cobalt, nickel, bronze or some other metals in different combinations, was designed to wear away after many revolutions in the blade. Its wear rate is designed so it will wear for a price that can provide maximum retention of the diamond crystals and protrusion from your matrix so that they can cut.
The diamond and bond interact with each other and is particularly approximately the maker to supply the best combination based on input from the cutting contractor given specific cutting requirements. Critical factors 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.