What Are The Advantages Of Coarse Diamond Saw Blade?

Diamond is the hardest substance in nature. Natural diamonds are called diamonds. Although artificial diamonds have been around for decades, they still cannot change the fact that diamonds are expensive. In fact, the same is true for synthetic diamonds. The larger the particle size, the more expensive the diamond.

So if these large particles of diamond are used in diamond saw blades to cut stone, will there be any difference? With such an idea, LINXING' s R&D engineers quickly invested in this job, using diamonds with large particles and diamonds with small particles to test separately, what kind of results did they get in the end?

We selected three groups of diamonds 16#-24#, 30#-40#, 50#-60# for testing. In order to make the test data more fair, we use the same weight of diamonds and the same ratio of powder to give the test data the most basic test basis. Shortly after the weighing, we put the three powders in the blender and blended them separately. In order to stir more evenly, we use laboratory stirring equipment to stir the three powders separately. The total time is 30 minutes, 10 minutes for each powder, to ensure more even mixing.

After stirring the material, it is cold-pressed, moulded, sintered, and the segment (40*4.2*13) is formed. In order to better match the three materials, in the sintering process, we give the three the same sintering temperature and holding temperature, the same pressure and holding time. After the sintering is completed, we take out three different segments, and the three segments can still see the situation of segments with different particle sizes according to the size of the diamond particles on the surface of the segment.

Select the same saw blade blank (350mm saw blade, blade blank thickness 3.2mm). We put the segment through a semi-automatic welding machine to fix the segment with the saw blade. In order to better maintain the fairness of the welding process, we use silver-copper solder pads with a silver content of 35% for welding, which ensures that there will not be too many problems in welding to the greatest extent. After welding, the saw blade is edged by the edger for half a minute. After the blade is edged out, the test and comparison test begins.

The first day: We tested and cut Maple-Red stone. Through the data comparison of three saw blades, we found that the smaller the particle size, the faster the cutting efficiency and the fastest consumption when cutting Shanxi-Black stone. For saw blades with larger particles, even the cutting does not occur, and the segment obviously cannot cut the edge. The preliminary judgment is that the number of diamonds involved in cutting is too small.

The second day: Replacement to cut the softer Shanxi-Black stone. There are some problems with the saw blades of the three types of saw blades through the second day. The cutting efficiency of the small-grained saw blades for cutting soft stone begins to decline, but it is not unacceptable. Medium-grained saw blades The saw blade cutting this kind of soft stone has obvious efficiency improvement. And the large particle saw blade cutting this kind of stone also has some efficiency improvement, but the improvement is not obvious.

Day 3: After the first two days of testing, we decided to cut some stones with moderate hardness--G654 stone. During the cutting process, it was found that the cutting sharpness of the large-grained stone began to decline significantly, while the medium-grained saw blades has been slightly improved.

In general, the coarse diamond saw blade has a good performance when cutting soft stone. If such a large-grained diamond is used for cutting marble or limestone, it should have a good effect. However, cutting hard stone can not achieve a strong cutting effect.

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The scope of application is crucial

The choice of cutting material - carbide, bimetal or diamond - depends on the materials being cut and their machinability. Diamond is known to be the hardest material and can therefore cut almost all materials - even the hardest. Of course this does not mean that diamond saw bands are fundamentally superior to other band saw blades: For example, in construction, case-hardened, tempering and tool steels carbide or bimetallic bands are usually used, which are quite sufficient for most materials. 

Diamond, on the other hand, is used for special applications and for cutting glass, graphite, silicon, hard coal, ceramics, concrete materials, CFRP, sintered materials, perforated bricks and clinker as well as to cut mineral building materials such as calcareous or natural stone. This is why diamond-coated band saw blades are primarily used in transportation such as aerospace, energy and recycling as well as construction and steel making. 

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Advantages of diamond band saw blades

Diamond-coated band saw blades offer the highest level of precision at high cutting speeds and performance. This special band saw blades can even be used when machining graphite, where cooling is generally not possible and therefore is performed dry. That’s why companies use diamond-coated band saw blades to make electrode blanks from graphite. Technically speaking, it is basically correct to describe the use of diamond-coated band saw blades as a cut-off grinding process. In contrast to graphite, water cooling is used during the sawing of optical glass and/or silicon. For comparably expensive materials, precise and materialsaving cutting is also crucial in order to ensure cost-effectiveness. Only diamond-coated band saw blades in this form can guarantee this. In addition, diamond band saw blades offer the advantage, under certain use conditions and constraints, that no chipping occurs at the contour edges during sawing and that hardly any reworking is necessary due to their excellent cutting surface.

Diamond-coated band saw blades with stainless steel carrier band can be used particularly efficiently when cooling with oil-free or corrosion-free coolants or even pure water, because the carrier band is not damaged from potential oxidation and decomposition during prolonged periods of downtime. Accordingly, the bands need to be changed less. In case of sporadic use, the saw bands can remain clamped on the sawing machine.

Know-how is what matters

Comprehensive advice, as offered by WIKUS, is crucial when selecting the right band saw blade. Because, depending on the material or the workpiece being machined, custom design of the occupation geometry is both expedient and possible. Furthermore, diamond-coated band saw blades have a wide range of applications, which is why both the use and, above all, the handling of diamond band saw blades require extensive know-how from skilled workers. That's why sawmills should be advised in advance by experts. Further education and training also help to increase safety when dealing with diamond-tipped band saw blades and to benefit fully from the advantages also in terms of efficiency. For this purpose, WIKUS founded the WIkademy®, a training center based in Spangenberg, Hesse. The program offers on-site seminars with a methodological mix of lessons and in-depth expertise.

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