877-755-1234

Diamond Tool Construction and Recommendations

 


Diamond Tool Construction

            Almost all modern diamond tools are manufactured using a method where very small diamonds and various metals are mixed and formed into a matrix that is fastened into the cutting edge of the tool.  As the metal matrix wears away in the “cutting process”, new diamonds project from the matrix to keep the cutting speed of the diamond tool relatively constant until the tool is worn out.

            There are three methods used to fasten the metal material to the blade or bit.

            (1)   Sintered   This is the lowest cost method of making a diamond bit or blade. The entire tool is heated along with the metal containing the diamonds and the metal matrix "fuses: to the steel core in a permanent mold reducing "build time".

            (2)   Brazed   The brazing process allows for much denser and higher temperature manufacturing of individual segments.  These segments are then individually brazed or silver soldered to the steel core of the diamond tool.  This is a much more labor intense process but allows a lot of flexibility in how hard or soft the metal matrx is.

             (3)   Laser Welded   Like the "brazing" process, each segment is individually made and then welded ("fused") to the steel core of the diamond tool with a high powered industrial laser machine. This is a quick process but requires a machine costing several hundred thousand dollars.

            The process of “cutting” with a diamond tool is not a cutting process at all, but instead it is a grinding process where the diamonds scratch the concrete into fine powder.

Dry Cutting VS Wet Cutting

            When ever possible, it is preferable to cut wet instead of cutting dry because of the respiratory danger associated with breathing dust when using a dry blade and the possibility of over-heating the tool if using a powerful machine.

Dry blades work better at higher rpm so air cools them better and the dust gets thrown off of the tool faster, reducing friction.  Cutting with a dry tool is a process using low to medium pressure for a few seconds and then free spinning the tool in air for a few seconds allowing the tool to cool.

Note:   Call Value Diamond Tool Company at 877-755-1234 if you have any questions or need recommendations.

 

Cutting Characteristics

            There are many factors that affect the cutting speed and wear rates of diamond tools.  Some of the most important of these are:

  1. Diamond Tool RPM

The faster the rpm, the slower the tool matrix will wear away, extending the tool life & vice versa.

  1. If the tool does not wear at the proper rate, the diamonds will not fall out at the proper rate and eventually the cutting of the tool will slow down as the diamonds lose their sharp edges.

  2. If the diamond tool rpm is too low, the metal matrix may wear faster than necessary, allowing the diamonds to fall out of the matrix before their ability to cut is fully utilized.

   B.   Tool Pressure Against the Material Being Cut

  1. Light tool pressure may allow the diamonds to dull without exposing new diamonds quickly enough, causing the tool to cut slowly.

  2. If excess pressure is used, the matrix may wear away too fast, allowing the diamonds to fall out of the matrix too quickly causing the tool to wear out fast.

 C.  Type of Aggregate In the Asphalt Or Concrete Being Cut

  1. Limestone aggregates are soft and usually only slightly abrasive and can be cut at higher rpm for good tool life and fast cutting speed.

  2. Flint and chert aggregates are hard and usually cut better at lower rpm.

 D.  The Type of Sand In the Mixture Of Asphalt or Concrete

  1. Sharp sand will wear away the metal matrix more quickly than rounded (river bed) type sand.  Use higher diamond tool rpm, less tool pressure and lots of water (if wet cutting) to help minimize this matrix wear.

  2. Dull sand may cause the matrix to wear away too slowly, causing the tool to cut slowly.  Slowing the rpm down, putting more pressure on the tool and, (if cutting wet) minimizing the cooling water flow, will help keep the tool “open” and cutting properly.

The Toughest Cutting Is a Situation Where the     Aggregate Being Cut Is Very Hard and the Sand Is Very Sharp.

This situation is difficult and requires careful operator attention the cutting pressure, rpm, and water flow (if wet cutting) to get a reasonable balance between cutting speed and tool life.  This type of cutting situation will cause diamond tools to be used up at 2-5 times the normal rate.

Note:   Call Value Diamond Tool Company at 877-755-1234 for more information.

 

The Age of The Concrete

  1. From approximately 4 – 12 hours after being poured, depending on temperature, humidity, weather and admixtures, concrete is considered “green” and is still soft.  When cut with a diamond tool, sand will pull out of the concrete and severely wear the matrix and the steel core of the blade requiring a very tough and hard metal to hold the diamonds and a special under-cut resistant core.

  2. From approximately 12 – 24 hours after pouring, the concrete is hardening and the sand does not pull out of the concrete quite so easily when the diamond tool cuts it, requiring a slightly softer metal matrix to hold the diamonds.

  3. From approximately 24 – 72 hours the concrete is hardening further and the sand is locked into the concrete reducing the segment and core wear.  A blade with a softer matrix is necessary to cut fast and not leave a ragged edge on the cut line.

Note:   Call Value Diamond Tool Company at 877-755-1234 for more information and recommendations.

 

Sand and Aggregate Size in Concrete

            The larger the aggregate in concrete the harder it is to cut. The smaller the aggregate the easier it is to cut. Experience with diamond blades and their performance will minimize the cost of cutting, grinding and drilling concrete and asphalted concrete.  The technicians at Value Diamond Tool can help you choose the best tool for your application with a simple phone call.

Note:   Harder metal matrix bonds will last longer and softer bonds will cut faster saving labor.

Asphalt Sawing

            Cutting asphalt is much like cutting “green concrete: and requires a hard metal matrix to hold the diamonds and a special “under cut” resistant steel core. Asphalt cuts fast as compared to cured (old) concrete but is affected by aggregate size, hardness, type of sand, and the horsepower of the machine being used. 

Note:   Call Value Diamond Tool Company at 877-755-1234 for a professional recommendation on the best specification to use for your application.

 

Ceramic Tile Cutting

            Ceramic is very hard and only slightly abrasive, but chips very easily.  It is best to cut ceramic tile with a semi-soft bond continuous rim blade to minimize chipping.  Any machine from ˝ - 2 ˝ HP is adequate to cut tile.

 

Masonry Cutting

  1. Cutting concrete block can vary greatly depending on aggregate used; amount of cement used, and the sharpness on the sand used. 

  2. Brick can vary widely depending on material used, time in the kiln, glazing etc., etc.  Brick can vary in compressive strength from 2,500 psi to over 20,000 psi, requiring a considerable range of matrix metal hardness to cut effectively. 

Note:   Call Value Diamond Tool Company at 877-755-1234 for a professional recommendation on the best specification to use for your application.

 

Stone

            This is the most difficult material to categorize as stone comes in every hardness, abrasiveness, compressive strength, etc., etc.

Note:   Call Value Diamond Tool Company at 877-755-1234 for a professional recommendation on the best specification to use for your application.

 

Conclusion

            The single most important factor in properly choosing diamond tools is to match the tool to the material you want to cut and the machine you have available. If you do this properly, cutting with diamond tools will be both fast and economical.

Note:   If you have any questions or need a recommendation, call Value Diamond at 877-755-1234 and we will do our best to help you.

 

 
Value Diamond Tool Company
Website and Online Store:  http://www.valuediamond.net 
Toll Free:  877-755-1234 | Toll Free Fax: 877-755-1235
Email: info@valuediamond.net

More Reading:

  • autumn-omit

  • avoidance-strap

  • awkward-roast

  • axe-collar

  • baggage-amongst

  • bake-cautious

  • barber-berry

  • basin-omission

  • basket-width

  • bean-drawer