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The proper use of diamond blades is essential to providing economical solutions for that construction industry. The Concrete Sawing and Drilling Association, that is dedicated to the advancement and professionalism of concrete cutting operators, offers operators the equipment and skills needed to understand and make use of diamond blades for optimal performance. CSDA accomplishes this goal by providing introductory and advanced training programs for operators with hands-on lessons in flat sawing, wall sawing, core drilling, wire sawing and hand sawing. In addition they offer some safety and training videos together with a safety handbook in support with their effort to coach sawing and drilling operators. This information will discuss the use of diamond tools, primarily saw blades, and provide strategies for their inexpensive use.

Diamond is well known since the hardest substance proven to man. One would feel that an operator of Core cutting machine could use the hardness characteristics of diamond to maximum advantage, i.e. the harder the better. In practice, this may not be always true. Whether the operator is cutting or drilling concrete, stone, masonry or asphalt, the diamonds must wear to be able to increase the performance in the cutting tool. This post will examine the role diamond plays in cutting tools and how an operator are able to use analytical ways to maximize the use of the diamond cutting tools thereby increasing productivity and maximizing the life of the tool.

Diamond crystals might be synthetically grown in numerous types of qualities, shapes and forms. Synthetic diamond has replaced natural diamond in nearly all construction applications for this reason capacity to tailor-create the diamond for that specific application. Diamond is grown with smooth crystal faces in the cubo-octahedral shape along with the color is typically from light yellow to medium yellow-green. Diamond is additionally grown to some specific toughness, which generally increases since the crystal size decreases. How big the diamond crystals, commonly referred to as mesh size, determines the number of diamond cutting points exposed on the outside of a saw blade. In general, 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 several interrelated considerations which 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, commonly referred to as CON, is really a measure of the level of diamond contained in 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 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 can certainly make the bond act harder while also increasing diamond tool life. Optimum performance can be achieved once the diamond tool manufacturer utilizes her or his experience and analytical capabilities to balance diamond concentration and also other factors to accomplish optimum performance to the cutting operator.

Diamond Shape & Size

Diamond shapes may 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 typically better suited for stone and construction applications. The blocky shape provides greater resistance to fracturing, and thus provides the maximum variety of cutting points and minimum surface contact. It has a direct impact in the lower horsepower need for the transformer 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 and is also more suited for less severe applications.

Synthetic diamond may be grown in a range of mesh sizes to fit the preferred application. Mesh sizes are often in the plethora of 20 to 50 United states Mesh (840 to 297 microns) in construction applications. The actual size of the diamond crystals, plus the concentration, determines the level of diamond that might be exposed on top of the cutting surface of the segments in the blade. The exposure, or height, of diamond protrusion (Figure 3) influences the depth of cut of each and every crystal, and subsequently, the opportunity material removal rate. Larger diamond crystals and greater diamond protrusion can result in a potentially faster material removal rate if you have enough horsepower available. On the whole, when cutting softer materials, larger diamond crystals are being used, so when cutting harder materials, smaller crystals are employed.

The diamond mesh size in the cutting tool also directly pertains to the amount of crystals per carat along with the free cutting ability to 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 will have 1,700 crystals per carat.

Specifying the correct mesh dimensions are the job from the diamond tool manufacturer. Producing the right amount of cutting points can maximize the lifetime of the tool and reduce the appliance power requirements. For instance, a diamond tool manufacturer might want to utilize a finer mesh size to boost the number of cutting crystals on the low concentration tool which improves tool life and power requirements.

Diamond Impact Strength

All diamond will not be the same, and this is especially true for the strength of diamonds employed in construction applications. The capacity of your diamond to stand up to an impact load is typically called diamond impact strength. Other diamond-related factors, for example crystal shape, size, inclusions as well as the distribution of those crystal properties, play a role inside the impact strength also.

Impact strength can be measured and is typically called Toughness Index (TI). Moreover, crystals are also subjected to quite high temperatures during manufacturing and in some cases through the cutting process. Thermal Toughness Index (TTI) is definitely the way of measuring the ability of the diamond crystal to withstand thermal cycling. Subjecting the diamond crystals to high temperature, letting them go back to room temperature, and after that measuring the alteration in toughness makes this measurement helpful to a diamond tool manufacturer.

The manufacturer must pick the right diamond based on previous experience or input from the operator inside the field. This decision is situated, partly, about the tool’s design, bond properties, material being cut and Transformer core cutting machine. These factors must be balanced by your selection of diamond grade and concentration that can provide the operator with optimum performance with a suitable cost.

In general, a greater impact strength is needed for additional demanding, harder-to-cut materials. However, always using higher impact strength diamond that may be more costly will not always benefit the operator. It may not improve, and may 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 in the blade (Figure 4). The diamonds are held in place through the segment, which is actually a specially formulated combination of metal bond powders and diamond, that were pressed and heated in the sintering press from the manufacturer. The diamond and bond are tailor-intended to the precise cutting application. The exposed diamonds on the surface of your segment perform the cutting. A diamond blade cuts in the manner just like how sand paper cuts wood. As being 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 with the material, the diamonds chip away on the material being cut (Figure 6).

The optimal lifetime of a diamond starts as a whole crystal that becomes exposed throughout the segment bond matrix. Because the blade begins to cut, a compact wear-flat develops along with a bond tail develops behind the diamond. Eventually, small microfractures develop, however the diamond remains cutting well. Then this diamond begins to macrofracture, and in the end crushes (Figure 7). This is actually 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 consistently act as its cutting action is bought out by the next layer of diamonds which can be interspersed during the entire segment.

The metal bond matrix, which may be made from iron, cobalt, nickel, bronze or some other metals in a variety of combinations, was designed to wear away after many revolutions in 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 so they can cut.

The diamond and bond interact with each other which is as much as the maker to deliver the best combination dependant on input from your cutting contractor given specific cutting requirements. Critical factors for sides to address would be the bond system, material to get cut and machine parameters. The mix of diamond and bond accomplishes a variety of critical functions.