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Synergy Material Technology
a new highway to Superhard Material Industry
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Saw blade problems
Common problems encountered in the use of diamond saw blades are:
Over exposure of the diamond
Heavy diamond damage
Diamond glazing
Diamond polishing
Diamond pull-out
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Problem |
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| Over exposure of the diamond A large portion of the diamond (up to a third) is exposed above the bond. The tail behind the diamond is low, offering little support. Possible causes: 1. initial overdressing of the tool during manufacture 2. diamond concentration too low and/or abrasion resistance of bond too low Resulting in: a. high achievable cut rate b. poor tool life due to loss of working diamonds |
| Heavy diamond damage A large portion of the diamonds at the surface show heavy fracture or cleavage. The height of protrusion of the diamonds is generally low. Possible causes: 1. diamond too friable for application 2. diamond mesh size too large for application 3. excessive vibration due to machine tool/workpiece location 4. general tool abuse Resulting in: a. blade dulling and reduced cut rate if the bond is too hard, excessive tool wear if the bond is less abrasion resistant Note When cutting extremely hard workpiece materials more diamond fracture will be observed. This is a normal wear characteristic. The above relates to unusual levels of impact damage on medium to soft workpieces. |
| Diamond glazing The surface of the segment is smooth i.e. no protrusion of the diamond above the bond. Possible causes: 1. diamonds too friable for application 2. bond too hard for application 3. diamond concentration too low for application 4. tool speed too high (excessive impacts of the diamond) Resulting in: a. good initial cut rate reducing rapidly to zero (increasing feed force will not help and tool must be redressed if failure recurs a new tool specification is required) b. if redressing is continued, overheating, segment or tension loss may occur (this is exacerbated by an increase in vibration) |
| Diamond polishing The working diamonds are still protruding but large wear flats have developed. Possible causes: 1. impact resistance of the diamonds is too high 2. diamond size is too large 3. diamond concentration too high 4. insufficient work load on the diamonds 5. diamond type prone to wear flatting Resulting in: a. high initial cut rate which gradually slows with corresponding increase in power drawn b. deviation in cut, if operation is continued |
| Diamond pull-out Large percentage of deep holes. These occur when diamonds are prematurely pulled out of the segment Possible causes: 1. impact resistance of the diamonds is too high 2. bond does not retain diamond due to: excessive diamond surface graphitisation or excessive bond porosity 3. excessive heat generation during operation 4. poor diamond distribution Resulting in: a. glazing, if a very hard bond is used b. rapid wear, if a soft bond is used |