This section should help to identify some of the challenges that are inevitable when using Diamond products.
This section presents the possible causes of the problems then proceeds to guide you through any necessary action to identify and eliminate them.
It is of paramount importance that all Diamond product specifiers, supervisors and operators are aware of the best practice in the use of products contained within this brochure that will enhance the product’s life, along with operational performance and efficiency.
Diamond segments are attached to the core by brazing with the use of solder positioned between the segment and the core. This is then heated to approximately 2000oC until the solder melts and makes a bond between the two pieces.
HIGH FREQUENCY WELDING
By the action of a high frequency electronic current the binder melts and bonds the two parts together.
LASER WELDED SEGMENTS
Laser welding represents the latest advancements in Diamond blade fabricating technology. Diamond segments are attached to the core by laser beam. The transitional area of laser weld is even stronger than the segment or the core. Laser welded blades can be used wet or dry. The requirements of the application or equipment involved in using Diamond products may at times necessitate the use of water for cooling the product or maximising blade performance, despite the blade being laser welded.
Wet cutting products must be used with water to keep the segments cool during the cutting operation. Water also assists the product to perform at its maximum efficiency. Under no circumstances should you use the product without adequate water flow. Cutting without water on these products will cause excessive heat build up, resulting in poor performance and blade damage in the form of cracks in the steel centre. The braze transitional area holding the segment onto the centre may melt, resulting in segment loss.
Dry cutting is possible with low horsepower machines for high speed and intermittent use. Although no water is required, blades must be cooled with airflow around the blade to dissipate the heat. Dry cutting blades are only recommended for intermittent cutting. Every 10 – 15 seconds the blade should be allowed to rotate out of the cut at maximum RPM for several seconds to allow the blade to cool. Operators should not use dry Diamond blades for long continuous full depth sawing in one single pass. Any cuts deeper than 4 cm should be step cut – ie make several shallow passes until the required depth of cut is reached. On asphalt, operators should avoid cutting into the sub-base of roads as this will cause rapid wear of the segments. Do not force the blade into the material, remember to let the tool do the work, any undue force will cause vibration and overheating which will adversely affect the life and the performance of the product. Overheating should be avoided particularly when cutting steel reinforced materials such as lintels. Forcing the product into the application is the most common cause of overheating. If signs of overheating are present, such as blue discolouration under each segment of the core, then the blade will require redressing. Forced cutting of hard aggregates, or hard low abrasive materials can reduce the cutting ability of the blade. The operator should dress the Diamond blade by using it in a soft abrasive material such as sandstone or abrasive blocks which will then restore the cutting properties.
The most common problem encountered by diamond blade users is blade wear. It is also the most difficult to accurately evaluate. It is impossible to predict the life performance of a blade that is operating in conditions with so many variables.
To consistently monitor the life and performance of the blade it is essential to calculate the variables including the material, inch metres cut, depth of cut, water supply, water quality and quantity used, and the amount of pressure applied by the operator, rather than the hours, days or weeks that the blade has been used. Trying to compare the performance of a blade with another is almost impossible due to the large amount of variables encountered.