|
Diamond
Blade / Sawing Problem
Solving / Trouble Shooting
Successful
diamond sawing is both an art & science. Requiring
the proper understanding of how to use speeds and feed rates, coolants, flanges,
& material holding fixtures to maximize cutting efficiency, diamond blade and
cut quality. While this understanding is best gained through
experience, even new diamond blade users can quickly become proficient by
learning and applying some basic principles of diamond sawing. We
are here to help you get the most out of your diamond sawing operation. BELOW
IS A GUIDE OF MOST COMMON DIAMOND SAWING PROBLEMS & SOLUTIONS ON HOW TO
RESOLVE THEM. If
you have a problem than is not addressed by this guide, have a question, need further guidance or assistance
please contact us by email, phone, or fax. For urgent support, you can
contact us at: Phone:
(661) 257-2288. Our experienced engineers will provide valuable
suggestions on how to improve you diamond sawing operation. We
encourage you to provide as much information as possible on your
application problem occurred, and periodically update us on your diamond
blade progress.
We also highly encourage you to check the SUPPORT part of our web
site. This will answer most questions you may have.
A
FEW WORDS ABOUT DIAMOND BLADE LIFE & PERFORMANCE
Material
Hardness + Density + Cutting Depth + Material Shape/Geometry + RPM's +
Feed Rate + Coolant Used + Cutting Equipment Type/Condition + Flange
Size/Exposure + Material Holding Method + Operator Experience
=
DIAMOND BLADE LIFE
& OVERALL PERFORMANCE |
 |
Diamond Blade Life
& Overall Performance will vary with material hardness, density, thickness,
& cutting depth. Few other factors that play a role in diamond blade life
& performance include: RPM's (cutting speed), Feed Rate, Geometry (shape) of Material, Coolant being Used,
Coolant feed rate and Direction. Cutting Equipment, Material Clamping Method
& experience of operator. While there is now way of accurately predicting
Life of your diamond blade. It can be optimized by following Principals
of Proper Diamond Blade / Tool Usage.
There may also be some experimenting, as well as trial & error involved in
the part of the end user. Highly experienced diamond blade users may find some
variations in diamond blade life or performance even when working on same
material & application. While this phenomena is not too common, it does
occur. The machining environment around us is constantly changing. A slight
change or variation in any variable can have significant impact on your diamond
sawing results. Material being cut can vary in composition or density even
when coming from same manufacturer or source. Slight change in coolant feed
rate, coolant direction, RPM's, even the way the material is held in place can
make the difference. Frequently the cause of the problem may not be obvious and
may take as much as several failed attempts to surface.
When
encountering problems or variation in diamond blade performance.
Few stop
to think about or carefully examine their cutting process. Many users
immediately suspect quality of the diamond blade and are quick in labeling the
drill "Defective" or "Poor Quality". This is very rarely the case. Usually in over 90%
of these cases the diamond blade itself was not at fault. Most Respectable &
Experienced Diamond Blade Manufactures have rigid quality control and inspection
processes set in place.
|
Controlling everything from raw material input, output,
to final inspection. As well as field test blades randomly.
What a number of diamond blade users don't realize the
technical aspects & delicate nature of diamond sawing/machining process. What is important to understand is that almost
all diamond blade users, regardless of experience or technical background
will make some type of an unintended operator error while at
some point in their career.
With this in mind, UKAM Industrial Superhard Tools has assembled a list of
most common diamond blade operator errors made by users in
most industries & applications. Looking through this guide will help
you RESOLVE MOST COMMON DIFFICULTIES you may have in
using your diamond blades, as well as AVOID MOST COMMON
PROBLEMS in the first place.
Common
Problems |
Solution /
Prevention |
Material Overheating
|
Not enough coolant.
Power water supply. Increase amount of coolant
|
Material/Saw Vibration
|
Small flange
diameter is the largest cause of blade vibration.
-
Change
Blade Tension
-
Slow
Down Feed Rate
-
Check
saw shaft, it may be worn out
-
Check
Flange Tightness, lack of tightness causes vibration
-
Make
sure you saw does not vibrate
-
Make
sure your table does not vibrate
-
Make
sure your table is set up perpendicularly
-
Make
sure your material is securely held in place
-
When
blade speed slows down, proceed to dress
|
Excessive
Chipping
|
-
Use
Finer Diamond Mesh (grit size) blade
-
Reduce
Speed, RPM & Feed Rate
-
Use
appropriate coolant for the material / application such as
synthetic water soluble coolant
-
Make
sure that your material is securely held in place and does not
move while being cut.
-
Check
condition of your saw to make sure it is not out of order or
parts need replacement
-
Check
to see if sufficient amount of coolant is reaching the cutting
zone.
|
Excessive Burrs
on Material Edges
|
-
Use
Finer Diamond Mesh (grit size) blade
-
Reduce
RPM and Feed rate as needed
-
Use
higher Diamond Concentration Diamond Blade
-
Check
to see if sufficient amount of coolant is reaching the cutting
zone.
|
Blade is Cutting
Very Slow
|
-
Use a
dressing stick made from alumina oxide or silicon carbide to
dress the blade (sharpen diamonds / rexpose diamond layer)
-
Cut
into dressing stock 10 to 20 times. Or as much as necessary,
until blade starts near same speed as when it was new.
-
Increase
the RPM and Feed Rate as needed
|
Blade is Not
Cutting
|
-
Make
sure the RPM's recommended for the specific diamond blade you
are using
-
Use a
dressing stick made from alumina oxide or silicon carbide to
dress the blade (sharpen diamonds / rexpose diamond layer)
-
Cut
into dressing stock 10 to 20 times. Or as much as necessary,
until blade starts near same speed as when it was new.
-
Increase
RPM (speed)
-
Improper
blade specification. Diamond Concentration, Mesh Size, and
Bond Hardness is inappropriate for material being cut. Use
different blade with right bond type, hardness, concentration
and grit size for material being cut. Contact us for
recommendation.
|
Blade is Wobbling
(not cutting straight)
|
-
Make
sure the size of flanges on your cutting machine are
appropriate for use with blade diameter and thickness you are
using.
-
Make
sure the exposure of blade is appropriate for size and dimensions
of material you are cutting.
-
Increase
size of your saw flanges by using diamond wheel
stiffeners.
-
If
blade is dished, send to us to flatten or purchase new diamond
wheel.
-
Check
condition of your saw to make sure it is not out of order or
parts need replacement
|
Short Blade Life
|
-
Improper
blade specification. Diamond Concentration, Mesh Size, and
Bond Hardness is inappropriate for material being cut. Use
different blade with right bond type, hardness, concentration
and grit size for material being cut. Contact us for
recommendation.
-
Check
to see if sufficient amount of coolant is reaching the cutting
zone.
-
Make
sure the exposure of blade is appropriate for size and dimensions
of material you are cutting.
|
Low cutting rates
|
-
Smeared
material on the blade
-
Too
low a cutting speed and/or load
-
Redress
blade at <100 grams force
and <200 rpm speed
-
Increase
cutting speeds and loads
-
Rotate
specimen to minimize cutting area
|
Blade Diamond
Section Breakage
|
-
Improper
blade dressing
-
Insufficient
clamping of the specimen
-
Too
high an initial load
-
Distribute
Coolant Evenly
-
Secure
specimen with a rubber mounting pad
-
Reduce
initial loading to set cutting kerf
|
|