Diamond circular saw blade mainly refers to cutting saw blade for marble granite slab materials. Since the thickness of stone slab is not big, normally between 2cm to 10cm. This kind of saw blade has a small diameter, it’s wide application and large consumption. The diameter of diamond circular saw blade is generally between 105-650 mm.
Factors that affecting efficiency and life of diamond slab circular saw blade
Usage index of diamond slab circular saw blade
There are three main using indexes of diamond slab circular saw blade, they are service life, cutting efficiency and cutting quality.
Service life of diamond slab circular saw blade
Service life of diamond slab circular saw blade refers to the total cutting time from the beginning of the saw blade to complete consumption of diamond segments. The durability time can also be used as service life measurement index of diamond circular saw blade, that is, the area of stone slabs cut by diamond segments or the extended length of the sawing.
Cutting efficiency of diamond slab circular saw blade
Cutting efficiency refers to area of stone cutting by circular saw blade per unit time, which can be used to measure the sharpness or self sharpening of the saw blade.
Cutting Quality of diamond slab circular saw blade
Cutting quality refers to quality of the slab cutting surface, including surface flatness, straightness, parallelism, perpendicularity and edge integrity.
Factors that affect usage of diamond slab circular saw blade
Factors that affect efficiency and life of diamond circular saw blade are sawing parameters, diamond segment parameters and stone parameters. The parameters of diamond segment include particle size, concentration and bond hardness. The parameters of sawing process include linear speed of circular saw blade, cutting depth and feed speed. Stone parameters include stone hardness, structure, structure, composition, etc.
Linear speed of diamond circular saw blade.
In practice, linear speed of diamond circular saw blade is limited by the equipment conditions, circular saw blade quality and stone material properties. In terms of best service life and cutting efficiency of diamond circular saw blade, the linear speed of diamond saw blade should be selected according to properties of stones material which we are going to cut. When sawing granite, the linear speed of diamond circular saw blade should be set in the range of 25 ~ 35m/s. For granite with high content of quartz or other stone which are difficult to cut, a lower limit of saw blade linear speed is suitable. In the production of granite brick, the diameter of diamond circular saw blade is small and the linear speed can reach 35m/s.
Sawing depth of diamond circular saw blade.
The sawing depth is an important parameter related to diamond wearing, effective sawing, sawing force and properties of stone being cut. Generally speaking, when the linear speed of the diamond circular saw blade is high, the small cutting depth should be selected. From the current technology, the diamond cutting depth can be selected between 1 ~ 10 mm. Generally, when cutting granite with large diameter saw blade, the sawing depth can be controlled between 1 ~ 2 mm, and the feed speed should be reduced at the same time. When the linear speed of diamond circular saw blade is large, the small cutting depth should be selected. However, when the saw performance and tool strength permit, the larger cutting depth should be taken as far as possible to improve the cutting efficiency. When the machining surface is required, small depth cutting should be adopted.
Feed sawing speed of diamond circular saw blade.
Feed speed means speed of sawing stone. This speed affects the sawing rate, the force on saw blade and heat dissipation in the sawing area. Its value should be selected according to the stone to be cut. Generally speaking, we can increase the feed speed when cutting a softer stone, such as marble. If the feed rate is too low, the diamond segment can be easily consume. However, when sawing granite with coarse grain structure and uneven hardness, the feed speed should be reduced, otherwise the saw blade vibration will cause diamond fragmentation and reduce the sawing rate. The cutting speed of granite is generally selected in the range of 9 ~ 12 m/min.
Factors that affect diamond segments
Diamond grain on segment.
The grain size used on diamond segment is normally in the range of 30 / 35-60 / 80. The harder the rock is, the finer the grain size should be selected. Because under the same pressure, the finer the diamond is, the sharper it is, which is conducive to cutting into hard rock. In addition, generally large stone diameter circular saw blade requires high cutting efficiency. A coarse grain size should be applied on this kind of large diameter of saw blade , such as 30 / 40 and 40 / 50. Small diameter circular stone saw blade has low cutting efficiency and requires smooth rock sawing section, so finer grain size, such as 50 / 60 and 60 / 80, should be selected. Single grain saw blade is sharp and efficient, and mixed particle size saw blade is durable and low efficiency.
Concentration of diamond segment.
The diamond concentration refers to the density of diamond distributed in the matrix of working layer (i.e. the weight of diamond contained in unit volume). The results show that the concentration of diamond is 100% with 4.4 carats of diamond per cubic centimeter, and 75% with 3.3 carat diamond. The volume concentration represents the volume of diamond in the agglomerate. When the volume of diamond accounts for 1 / 4 of the total volume, its concentration is 100%. The life of saw blade can be prolonged by increasing diamond concentration, because the average cutting force per diamond is reduced by increasing diamond concentration. However, the cutting efficiency and sharpness of the saw blade decrease with the increase of diamond concentration, which will inevitably increase the cost of the saw blade. Low concentration, coarse-grained, high cutting efficiency is a good choice. In the multiple layer diamond bit, the concentration of diamond in each layer is different. For example, in the sandwich cutter head with three-layer structure, a lower concentration of diamond is used in the middle part. During the sawing process, a middle groove is formed on the working face of the cutter head to prevent the saw blade from swinging, which is beneficial to the cutting quality. Different diamond concentration can be adjusted in 5-layer, 7-layer or more layer cutter head structure to make saw blade sharp, high machining efficiency and long service life. At the same time, low concentration of diamond can be used in the inter layer of the cutter head, SiC can also be added or metal sheet can be used as inter layer.
Hardness of segment bond.
Generally speaking, the higher the hardness of the bond, the stronger its wear resistance. Therefore, when sawing rocks with high abrasiveness, the bond hardness should be higher; when sawing soft rock, the bond hardness should be low; when sawing high abrasive and hard rock, the bond hardness should be moderate.
Factors affecting stone properties.
The higher the hardness of stone, the greater the cutting force. The higher the surface temperature of diamond stone circular saw blade is, the more serious the wear of diamond blade is.
Force effect, temperature effect and wear damage of stone diamond circular saw blade.
In the process of cutting stone, the diamond circular saw blade will be subjected to alternating loads such as centrifugal force, sawing force and sawing heat, which will cause the diamond circular saw blade to be worn.
In the process of sawing, the saw blade is affected by axial force and tangential force. Due to the force in the circumferential direction and radial direction, the saw blade is wavy in the axial direction and dish shape in the radial direction. These two kinds of deformation will cause uneven rock section, waste of stone, noise and vibration during sawing, which will lead to early damage of diamond agglomerations and decrease of saw blade life.
According to the traditional theory, the influence of temperature on the saw blade process is mainly manifested in two aspects: one is the graphitization of the diamond in the agglomerate; the other is that the thermal deformation force between diamond and matrix causes the diamond particles to fall off prematurely. The new research shows that: the heat generated in the cutting process is mainly transferred into the caking, the arc temperature is not high, generally between 40 ~ 120°C, while the grinding point temperature of abrasive grains is higher, generally between 250 ~ 700°C. However, the coolant only reduces the average temperature of the arc area, but has little effect on the temperature of abrasive particles. Such a temperature will not cause graphite carbonization, but will change the friction performance between the abrasive particles and the work piece, and cause thermal stress between diamond and additives, which will lead to the fundamental change of the failure mechanism of diamond. The results show that the temperature effect is the most important factor to damage the saw blade.
Due to the wear of the saw blade after a period of time, it often produces stress. The main forms of grinding damage are as follows: abrasive wear, local crushing, large area crushing, falling off, mechanical abrasion of bond along the cutting speed direction.
Abrasive materials wearing.
The diamond particles rub with the stone continuously, and the edges are passivated into a plane, thus the cutting performance is lost and the friction is increased. The results show that the surface of diamond particles is graphitized, the hardness is greatly reduced and the wear is aggravated.
The surface of diamond grain is subjected to alternating thermal stress and cutting stress, which will cause fatigue crack and local fracture, and show sharp new edge, which is an ideal wear form.
Large area crushing.
The diamond grains bear impact load when cutting in and out, and the protruding particles and grains are consumed prematurely.
The alternating cutting force makes the diamond particles slosh and loosen in the bond. At the same time, the bond is softened by the wear of the bond itself and the sawing heat. When the cutting force on the particles is greater than the holding force, the diamond particles will fall off.
Applications of Diamond Circular Saw Blade
Diamond Circular Saw Blade Manufacturering Details
Diamond Circular Saw Blade Packing and Shipping
Diamond Circular Saw Blade Specifications
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