Diamond Smart Cut

UKAM Industrial Superhard Tools

661-257-2288

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Blade Troubleshooting

Diamond & CBN Blade
Trouble Shooting Guide

Our illustrated troubleshooting guide was designed to help you optimize your cutting operations. It assists in diagnosing most possible issues that may arise when using precision and ultra-thin diamond & CBN cutting blades. This guide highlights the signs to watch out for, their potential causes, their impact on cutting performance, and recommended solutions for resolving these issues and preventing them in the first place. Additionally, please be sure to explore our KNOWLEDGE CENTER articles. You can also contact our technical support for further assistance.

Diamond Section Glazed Over

Possible Cause

Affect On Cutting Performance

Solution

Signs: Surface of diamond section is smooth with no visible signs of diamond protruding from bond matrix. 

Diamond crystal are too friable

Blade slow down and eventually stops cutting

Make sure the RPM's Recommended for that specific diamond blade you are using.

Bond Matrix is too hard

Blade & material overheats

Use a dressing stick mode from aluminum code or silicon carbide to dress the blade ( sharpen diamonds / expose diamond layer )

Cutting speed is too high

Possible Material Deformation

Cut into dressing stock 10 to 20 times. or as much as necessary. until blade starts near same speed as when it was new.

Cutting speed is too low

Possible Material burning, chipping, cracking

Increase RPM ( speed )

Insufficient coolant flow to cutting zone ( reaching this cutting area }

Possible diamond section breakage

improper blade specification. Diamond concentration, mesh size, and bond hardness in inappropriate for material being out. Use different blade with right bond type, hardness, concentration and gift size for material being cut. contact us for recommendation.

Inappropriate blade specification for the application

Possible Loss of blade

Over Exposed Diamond Crystals

Possible Cause

Affect On Cutting Performance

Solution

Signs: Bond Matrix wears away before the diamond crystals. There is insufficient amount of bond matrix to support  the over exposed diamond crystals on the cutting edge face. Hence the diamond crystals are released from the bond matrix prematurely resulting in low blade life. There is visible amount of diamond crystal pullout at cutting edge.  

Diamond Bond is too Soft for the Application

Blade Cuts very bad

Reduce Feed Rate or Reduce RPM's

Inappropiate Blade Specification

Super bad blade wear

Change Blade Specification

Diamond Crystal Type, shape, coating inappropi- ate for the material being cut

Very Short Blade Life

User Harder Bond Matrix

Feed Rate / Lead is too high for the RPM's used

Inconsistent Cutting Performance

Excessive Premature Diamond Loss

Possible Cause

Affect On Cutting Performance

Solution

Signs: Diamond section show signs of high amount of lost diamond crystal from the bond matrix.

Diamond type, grade, shape, hardness, coating in inappropiate for the Blade Specification

Blade Cuts very fast

Use different blade with right bond type, hardness, concentration and grit size for material being cut. Contact us for recommendation

Feed rate is too high for the application

Fast Blade wear

Reduce Feed Rate or Reduce RPM's

Excessive amount of Horse Power of the cutting machine is used

Short Blade Life

Change Blade Specification

Bond Hardness too soft for the application

Inconsistent Cutting Performance

Use Harder Bond Matrix

Incorrect RPM's [too high or too low for the application]

Possible Material Scratches

Possible Material Deformation

Slow Cutting Speeds

Power Inefficiency

Crushed Diamond Crystals

Possible Cause

Affect On Cutting Performance

Solution

Signs: Diamond crystals in bond show signs of high amount of fracture. Diamond crushed at the matrix level. There is no protrusion, diamond crystal has lost its cutting properties.

Diamond type is too Friable

Blade Cuts very fast

Use Correct RPM's [not too high and not too low]

Diamond Particles are too large or blocky

Fast Blade wear

Use Correct Blade Specification

Excessive blade pound- ing or vibration

Short Blade Life

Reduce Feed Rate

Inappropiate blade mounting

Inconsistent Cutting Performance

Optimize Coolant Flow & Application

Flanges wear, unclear flanges, or material particles providing uneven mounting of blade

Slow cutting speeds

Worn out arbor or bearings

Chipping

Incorrect Material Fixturing / Holding Method

Host generation & stress to material

Inappropriate Bond Hardness or Blade Specification

Possible material deformation

Loss of output & Effciency

Diamond Crystal Premature Loss Of Sharp Point

Possible Cause

Affect On Cutting Performance

Solution

Signs: Diamond crystal premature glazing (loss of sharp point) and poor exposure from the bond matrix.

Diamond Crystal too high. Impact resistance

Inconsistent cutting speed

Use Finer (smaller) Diamond Grit Size

Diamond Crystal too large. for the application

Inconsistent cutting performane

Use lower Diamond Concentration Blade

Diamond Concentration is too high for the application

Blade & Material overheating

Dress the Blade when needed and periodically to maintain optimum diamond crystal exposure

RPM's are too low or too high

Possible material chipping & burning

Use the Right Cutting Equipment that has sufficient HP motor

Cutting machine has insufficient Horse Power for diamond crystal to have enough force to grind into the material

Possible diamond section breakage

Use Correct RPM's (not too high and not too low)

Insufficient amount of coolant is reaching the cutting

Possible loss of blade tension & flatness

Optimize Coolant:
Check to see if sufficient amount of coolant in reaching the cutting zone.

  • Make sure coolant nozzle are properly aligned, positioned, and enough coolant velocity to provide optimum flow of coolant into cutting zone
  • Make sure you are Using Optimum Coolant for the Application [check mix ratio, and condition of the coolant to make sure it is properly being filtered and change when and if needed]

Inappropiate Coolant Used for the Application

Blade is not periodically Dressed when needed or incorrectly dressed

Inappropriate Blade Specification for the Application

Excessive amount of Material [Swarf Particles in Coolant]

Blade Wobble

Possible Cause

Affect On Cutting Performance

Solution

Signs: Blade flexing while cutting (not cutting straight).

Flange diameter too small for the blade diameter and thickness

Excessive Chipping

Make sure the size of flanges on your cutting machine are appropiate for use which blade diameter and thickness you are using.

Too much blade exposure for size and dimension of material you are cutting

Irregular kerf width

Make sure the exposure of blade is appropiate for size and dimension of material you are cutting.

Insufficient coolant supply to cutting zone

Possible Blade Breakage

Increase size of your saw flanges by using diamond wheel stiffeners.

Cutting Saw is missaligned or blade not properly installed

Possible damage to holding fixture

If blade is dished send to us to flatten or purchase new diamond wheel.

Possibly the blade was mishandled prior to mounting

Check condition of your saw to make sure it is not out of order or parts need replacement.

Excessive Feed Rate and / or RPM's

Make sure the RPM's and feed rate is appropriate for the application.

Not Appropiate Blade Specification selected for Application

Make sure the blade specification is appropiate for the application.

Material not properly secured / fixtured

Make sure the material is properly secured in appropiate material holding fixture and does not move.

Blade Lost Its Tension/Flatness

Possible Cause

Affect On Cutting Performance

Solution

Signs: Blade not completely flat while placed against flat surface.

Not sufficient coolant amount

Blade can no longer be used

Minimize Blade Exposure

Blade not properly mounted

Chipping

Use a thicker blade if possible

Inappropiate blade Specification

Not Straight Cut

Optimize the mounting to minimize vibration and blade loading

Inappropiate RPM's of Feed Rate

Wider Kerf Width

Optimize the coolant flow & application

Material not properly secured

Possible Material Deformation

Optimize the cutting parameters to minimize loads

Not following recommended dressing process

Possible Blade Breakage

Check the RPM's to make sure they are not too high or too low

Too High Blade Exposure

Process Inconsistency

Make sure the material to properly secured / fixtured and doesnot move while cutting

Bond Hardness too High

Loss of Productivity

Reduce Feed Rate

Diamond Crystal Size too Small

Higher Cutting Cost

Use Optimum Blade Specification

Broken Diamond Section

Possible Cause

Affect On Cutting Performance

Solution

Signs: Diamond Section Breaks and flies off while cutting.

Improper blade dressing

Possible damage to material

Use a mechanical dressing fixture

Insufficient clamping of specimen

Possible injury to operator or surrounding environment

Secure specimen with a rubber pad

Too high on initial load / feed rate

Process Inconsistency

Reduce initial loading to not cutting kerf

Material Not Properly Secured and shifting/ moving while cutting

Higher process cost

Distribute Coolant Evenly

Too high Blade Exposure

Check the flange condition

Incorrect Blade Specification

Minimize Blade Exposure

Blade Incorrectly Mounted

Check the saw axis movement x & y if applicable

Burn on Flanges

Try a lower Diamond cone to minimize loads

Incorrect RPM's for the Application

Use a thicker blade if possible

Coolant not effectively or insufficiency reaching the cutting zone

Optimize the mounting to minimize vibration and blade loading

Cutting Saw Out of Condition / Not well Maintained

Optimize the coolant flow & application

Optimize the cutting parameters to minimize loads

Dress the Blade When Needed

Check the RPM's to make sure they are not too high or too low

Make sure the material is properly secured / fixtured and does not move while cutting

Check condition of machine and spindle to make sure it is not out of alignment or have excessive run out / vibration while cutting

Crack In Dimond Section

Possible Cause

Affect On Cutting Performance

Solution

Signs: Visible Crack in Diamond Section, or changed in cutting sound/ or sharp change in cutting performance.

Incorrect RPM's (too high or too low)

Blade diamond section Breakage

Check the RPM's to make sure they are not too high or too low

Too High Feed Rate

Possible damage to material

Reduce Feed Rate

Coolant not effectively or insufficiency reaching the cutting zone

Possibly injury to operator or surrounding environment

Optimize Coolant:
Check to see if sufficient amount of coolant in reaching the cutting zone.

  • Make sure coolant nozzle are properly aligned, positioned, and enough coolant velocity to provide optimum flow of coolant into cutting zone
  • Make sure you are Using Optimum Coolant for the Application [check mix ratio, and condition of the coolant to make sure it is properly being filtered and change when and if needed]

Process Inconsistency

Loss of Productivity

Higher Cutting Cost

Nick Of Diamond Section Chipped Out

Possible Cause

Affect On Cutting Performance

Solution

Signs: Piece of Diamond Section visibly chipped out for the blade kerf. 

Material Not Correctly Clamped / Fixtured in vice / chuck

Blade will not be safe to use (and should be discarded)

Check Condition of Mounting Flanges

Incorrect Matenal Holding Fixture

Check Condition of Spindle and its Runout

Material Moving while Cutting

Make Sure Blade is Properly Mounted

Incorrect RPM'S

Optimized the coolant :

  • Make Sure Blade is Properly Mounted
  • Optimize the cooling flow

Too Rah Feed Rate

Make Sure Blade Is Properly Mounted

Coolant not reaching cutting zone

Check the Condition of Cutting Machine

Minimize Vibrationte

Check to make sure the blade Is properly mounted and spindle is aligned and does not vibrate

Over Heated Blade

Possible Cause

Affect On Cutting Performance

Solution

Signs: Diamond Section Discoloration tension and possible of blade core. 

RPM's too fast for Inn application

Possible Chipping

Check the RPM's to make sure they are not too high or too low

RPM's too low for the application

Possible materiel deformation

Reduce Feed Rate

Feed rate too high for the application

Process Inconsistency & Insufficiency

Use Optimum Blade Specification Optimize Coolant:

Insufficient coolant amount reaching cutting zone

Premature blade failure

Optimized the coolant :

  • Check to see it sufficient amount of coolant is reaching the cutting zone
  • Make sure coolant nozzle are properly aligned. positioned, and enough cadent velocity to provide optimum flow of coolant into cutting zone

Inappropiate blade specification

Lost money in using more blades that needed for operation

Excessive Blade Wear

Possible Cause

Affect On Cutting Performance

Solution

Signs: Diamond Section Wearing in a very short period of time.

Inappropiate blade specification for the application

Loss of time in having to stop operations and change blades

Optimized the coolant:
Use different blade with right bond type. hardness, concentration and grit size for material being cat. Contact us for recommendation.

  • Try Larger (Coarser) Diamond Size
  • Try Harder Bond Matrix
  • Try Higher Diamond Concentration
  • Optimize the Diamond Type or Coating
  • If possible, try thicker blade
  • If possible, try a mounted or side grooved blade
  • Try Different Bond Type

Insufficient amount of coolant is reaching the cutting zone

Process inconsistency & Inefficiency

Optimize Coolant:
Check to see if sufficient amount of coolant in reaching the cutting zone.

  • Make sure coolant nozzle are properly aligned, positioned, and enough coolant velocity to provide optimum flow of coolant into cutting zone
  • Make sure you are Using Optimum Coolant for the Application [check mix ratio, and condition of the coolant to make sure it is properly being filtered and change when and if needed]

Inappropiate blade diameter and / or thickness for size and dimensions of material you are cutting

Lost Money in high blade cost

Optimize the Blade RPM's 8 Feed Rate:

  • Higher RPM's acts like a harder blade matrix
  • Higher feed rate increases loading and wear

Bond hardness too soft tot the application

Proper Maintenance For Blade 8 Equipment :

  • Make sure the blade is dressed when needed (recommended pre set process and also as needed)
  • Cutting equipment is properly and maintained (along with spindle and flanges)

Diamond concentration, Mesh size is inappropiate for material being cut

Incorrect RPM's and / or Feed Rate

Not Using Correct Coolant or Coolant Not Adequately Reach-ing Cutting Zone

Not Dessing Blade When Needed and / or Poor Equipment Maintenance

One Sided Chipping

Possible Cause

Affect On Cutting Performance

Solution

Signs: Chipping on only one side of the Kerf.

Coolant nozzles are not possIttoned property

Poor Cut Quality! Surface Finish

Check Alignment and runout of the saw spindle

Saw spindle is misaligned

Secondary Finishing Operatioans may be required to remove the damage caused

Check Positioning of the material and make sure it Is evenly hold down and secure

Material / wafer is not parallel to the spindle axis

Process Inconsistency

Check Condition of the saw flanges (clean and repair if necessary)

The flanges need cleaning

Loss of Productivity

Make Sure to Dress the Blade when and if necessary

Flanges require lapping

Higher Cutting Costs

Align Coolant Nozzles to make sure optimum amount of coolant is reaching cutting zone at best angle possible.

Use of hubless blades

Scrap Parts

Use synthetic water soluble coolant to reduce surface denslon, provide additional lubrication, reduce heat generation

Consistency Spaced Chipping

Possible Cause

Affect On Cutting Performance

Solution

Signs: Consistency Spaced Chipping on edge of the cut.

lnproper blade dressing

Poor Cut Quality! Surface Finish

Make Sure to Dress the Blade when and if necessary

Insufficient or Improper blade dressing

Secondary Finishing Operatioans may be required to remove the damage caused

Make Sure there is sufficient Blade Exposure just to cut the desired material thickness

Insufficient blade exposure

Process Inconsistency

Make Sure the RPMS and Feed Rate is optimized for the Application

Insufficient amount of coolant is reaching the cuffing zone

Loss of Productivity

Align Coolant Nozzles to make sure optimum amount of coolant is reaching cutting zone at best angle possible

Loss of Productivity

Use synthetic water soluble coolant to reduce surface dension. provide additional lubrication, reduce heat generation

Higher Cutting Costs

Scrap Parts

Excessive Backside Chipping

Possible Cause

Affect On Cutting Performance

Solution

Signs: Excessive & Visible Backside Chipping on back side of Material.

Substrate or wafer was incorrectly mounted on tape

Poor Cut Quality! Surface Finish

Use substrate and bond to wax to support material

Excessive air bubble between tape and material

Secondary Finishing Operatioans may be required to remove the damage caused

Optimize the feed rate / spindle RPM

Blade is cutting too deep Into the mounting media

Process Inconsistency

Dress the blade to minimize loading

Incorrect diamond size was selected

Loss of Productivity

Use Finer Size Diamond Crystal

Feed rate is too high

Higher Cutting Costs

Reduce Blade Exposure

Blade is worn and requires replacing

Scrap Parts

Use Optimum Malarial Holding Method

Coolant injections are misaligned

Align Coolant Nozzles to make sure optimum amount of coolant is reaching cutting zone at best angle possible

Blade exposure is too great

Use synthetic water soluble coolant to reduce surface tension, provide additional lubrication, reduce heat generation

Insufficient vacuum

If using vacuum chuck, make sure its optimum condition and enough force is used to keep the thin material [wafer or substrade in place]

Vacuum chuck requires resurfacing

Make sure the matedal Is properly mounted and there are no air gaps between material and substrate its mounted

Incorrect mounting media was selected

Blade was not properly dressed

Bottom Side Chipping

Possible Cause

Affect On Cutting Performance

Solution

Signs: Stress at bottom surface of material caused by the diamond fracture when exiting the cut can cause bottom chipping.

Higher temperature in bottom due insufficient amount Of coolant reaching the cueing zone

Poor Cut Quality! Surface Finish

Use Substrate and bond to was to support material

Material is not mounted ideally flat in holding lecture or by holding method

Secondary Finishing Operatioans may be required to remove the damage caused

Optimize the feed rate / spindle RPM

Possible air gaps between material and holding fixture

Process Inconsistency

Dress the blade to minimize loading

Unsupported fragile Material when mounted

Loss of Productivity

Add additives to the coolant to lower the surface tension of the coolant

Not Cutting into the mounted supporting material

Higher Cutting Costs

Optimize the diamond concentration to minimize the blade edge radius

Not Reducing the Feed Rate / Load when easing the cut

Scrap Parts

Use a higher wear bond to minimize loading

Use the thinnest blade possible to Minimize the radius on the blade edge

Adjust the cooling noozle and minimize the flow to reduce blade vibrations

Top Side Chipping

Possible Cause

Affect On Cutting Performance

Solution

Signs: Cracks similar in size with some slightly larger chipping along the edges.

Diamond crystals too coarse for the application

Poor Cut Quality! Surface Finish

Use smaller size diamond crystal

Feed rate too high

Secondary Finishing Operatioans may be required to remove the damage caused

Use different type of diamond crystal (such as uncoated)

Insufficient amount of coolant reaching the cutting zone

Process Inconsistency

Optimize the diamond concentration

Vibration of spindle or machine

Loss of Productivity

Try Softer Bond Matrix

Inapproppiate material mounting that causes material to move while cutting

Higher Cutting Costs

Try More Softer Bond Type

Excessive blade exposure

Scrap Parts

Minimize vibration

Insufficient blade exposure

Check to make sure the blade is properly mounted and spindle is aligned and does not vibrate

Incorrect diamond mesh size

Use optimum blade RPM'S

Blade is worn out

Make sure the material is mounted correctly. supported and does not move while cutting

Excessive feed rate

Minimize Blade Exposure

Material Is not parallel to spindle

Adjust the coolant pressure and align the nozzle now

Flanges need cleaning

Viewing optics are realigned with saw spindle

Material Micro Cracks

Possible Cause

Affect On Cutting Performance

Solution

Signs: Fracture in brittle materials & materials with different phases. Usually results when energy used to cut material is more than can be assorted by material.

Inappropriate blade specification used

Possible Material Breakage

Optimized the coolant :
Adjust the coolant pressure and align the nozzle flow

  • Make sure coolant nozzle are properly aligned. positioned, and enough coolant velocity to provide optimum flow of coolant into cutting zone
  • Make sure you are Using Optimum Coolant for the Application [check mix ratio, and condition of the coolant to make sure it is properly being filtered and change when and d needed)

Feed rate too high

Possible Material Deformation

Minimize Blade Exposure

Insufficient or incorrect clamping / fixtuting of the material

Possible Material I Part Hidden Detect

Use Different Blade Specification

Insufficient amount of coolant reaching cutting zone

Material Losses its Strength I Integrity

Use Optimum Blade RPM'S

RPM's too low or too high for the application

Use Optimum Feed Rate

Incorrect Blade Exposure

Too High Cut depth In Constation to Blade Thickness

Too High Cutting Speed

Material Not Correctly Supported

Material Pull Out

Possible Cause

Affect On Cutting Performance

Solution

Signs: Cavities in material that are left after the grains or particle of material are torn out of the material during cutting. This mainly applies for hard or brittle material only. 

Excessive heat and stress caused by inaPProninle cutting methods

Possible Material Deformation

Use Correct Blade Specification

Inappropriate blade specification used

Possible Material Breakage

Make sure coolant nozzle are properly aligned. positioned, and enough coolant velocity to provide optimum flow of coolant into cutting zone

RPM's too low or too high for the application

Possible Material / Part Hidden Detect

Use Optimum Blade RPM's

Insufficient support of material in the clamping / fixturing process

Material Losses its Strength/ Integrity

Use Optimum Feed Rate

Insufficient amount of coolant reaching cutting zone

Material Smearing

Possible Cause

Affect On Cutting Performance

Solution

Signs: Instead of material being cut it is pushed and moved across the surface. 

Insufficient amount of coolant reaching cutting zone

Possible Maternal Deformation

Use Correct Blade Specification

Inappropiate blade specification used [diamond grit sae typically is too fine]

Possible Material / Pan Hidden Detect

Use Optimum Blade RPM'S

RPM's too low or to high for the application

Secondary Finishing Operations may be required to remove the damage caused

Use Optimum Feed Rate

Bond Hardness to Hard

Use Softer Bond Matrix Blade

Feed Rate too High

Try Different Bond Type

Incorrect Bond Type

Make sure coolant nozzle are properly aligned, positioned, and enough coolant velocity to provide optimum flow of coolant into cutting zone

Material Scratches

Possible Cause

Affect On Cutting Performance

Solution

Signs: Grooves on the surface of the material typically produced by diamond crystals or material swarf abrasive particles.

Material swan abrasive particles trapped on surface of material that are not flushed away by coolant

Possible Material Deformation

Adjust the coolant pressure and align the nozzle flow

Polluted coolant, possible time to change the coolant

Possible Material / Part Hidden Detect

Make sure coolant nozzle are properly aligned, positioned, and enough coolant velocity to provide optimum flow of coolant into cutting zone

Insufficient amount of coolaant reaching cutting zone

Secondary Finishing Operations may be required to remove the damage caused

Make sure you are Using Optimum Coolant for the Application [check mix ratio, and condition of the coolant to make sure it is propedy being filtered and change when and if needed]

Inappropriate blade specification

Use Coned Blade Specification

Material Burning

Possible Cause

Affect On Cutting Performance

Solution

Signs: Small pieces of material debris at edges of cut kerf caused from the stress of the diamond micro fracture process.

Incorrect blade specification / diamond size

Poor Cut Quality / Surface Finish

Optimize Blade Specification :

Use different blade with right bond type. hardness, concentration and grit size for material being cut. Contact us for recommendation.

Incorrect RPM's

Secondary Finishing Operations may be required to remove the damage caused

Check the RPM's to Make sure they are not too high or too low

Incurred feed rate

Process Inconsistency

Reduce Feed Rate

Incorrect material mounting

Loss of Productivity

Optimize Coolant :

Check to see if sufficient amount of coolant in reaching the cutting zone

  • Make sure coolant nozzle are properly aligned. positioned. and enough coolant velocity to provide optimum flow of coolant into cutting zone
  • Make sure you are Using Optimum Coolant for the Application [check mix ratio, and condition of the coolant to make sure it is properly being filtered and change when and it needed]

Insufficient amount of coolant reaching cutting zone

Higher Cutting Costs

Scrap Parts

Possible Material Deformation

Possible Material / Pan Hidden Detect

Shell Type Chipping

Possible Cause

Affect On Cutting Performance

Solution

Signs: Mainly occurs in brittle materials, material breaks off in a shell shape. Usually these chips are large and similar to shell shape.

Diamond crystals too coarse for the application

Poor Cut Quality Surface Finish

Use smaller size diamond crystal

Feed rate too high

Secondary Finishing Operations may be required to remove the damage caused

Use different type of diamond crystal (such as uncoated)

Insufficient amount of coolant reaching the cutting zone

Process Inconsistency

Optimize the diamond concentration

Vibration of spindle or machine

Loss of Productivity

Try Softer Bond Matrix

Inappropriate material mounting that causes a 'needle! to move while cutting

Higher Cutting Costs

Try More Softer Bond Type

Excessive blade exposure

Scrap Parts

Minimize vibration

Insufficient blade exposure

Possible Material Deformation

Check to make sure the blade is property mounted and spindle Is aligned and does not vibrate

Incorrect diamond mesh size

Use optimum blade RPM'S

Blade is worn out

Make sure the material is mounted correctly, supported and does not move while cutting

Excessive feed rate

Minimize Blade Exposure

Insufficient supply of coolant in cutting zone

Adjust the coolant pressure and align the nozzle flow

Incorrect mounting

Incorrect speed ( RPM's )

Spindle is missaligned

Blade requires dressing

Material is not parallel to spindle

Flanges need lapping

Flanges need cleaning

Viewing optics are misaligned with saw spindle

Slanted Cut At The Kerf

Possible Cause

Affect On Cutting Performance

Solution

Signs: Uneven Kerf.

Excessive blade exposure

Not Straight Cut

Minimize Blade Exposure

Not Proper Blade Diameter

Blade Losses In Tension Flatness

Adjust the coolant pressure and align the nozzle low

Blade too Thin for the Cutting Depth

Possible Blade Breakage

Try Using Larger Blade Diameter

Feed Rate too High

Blade Stops Cutting

Try Using Thicker Kerf Blade

Incorrect RPM's [too high or too low for the application

Process Inconsistency

Use correct RPM's

Excessive Coolant Velocity 8 Incorrect Nozzle Positioning

Loss of Productivity

Reduce Feed Rate

Incorrect Blade Specification

Higher Cutting Costs

Check Condition of Mounting Flanges

Check Condition of Spindle and its Runout

Make Sure Blade is Properly Mounted

Use Optimum Blade Specification

Wider Cut At The Top

Possible Cause

Affect On Cutting Performance

Solution

Signs: Wider Kerf thickness at cut entrance.

Blade Lost its Kerf Edge Forrn

Not Straight Cut

Use Optimum Blade specification

Uneven Blade Wear

Process Inconsistency

Change Bond Matrix Hardness

Incorrect Blade Specification

Loss of Productivity

Change Bond Type

Bond Hardness too Hard

Higher Cutting Costs

Too High Diamond Concentration

Wider Cut At Top On One Side Or Both Sides

Possible Cause

Affect On Cutting Performance

Solution

Blade Lost its Kerf Edge Forrn

Larger Cut Width

Minimize Blade Exposure

Uneven Blade Wear

Process Inconsistency

Adjust the coolant pressure and align the nozzle flow

Incorrect Blade Specification

Loss of Productivity

Try Using Larger Blade Diameter

Bond Hardness too Hard

Higher Cutting Costs

Try Using Thicker Kerf Blade

Too High Diamond Concentration

Scarp Parts

Use Correct RPM's

Possible Material Deformation

Reduce Feed Rate

Check Condition of Mounting Flanges

Check Condition of Spindle and its Runout

Make Sure Blade is Properly Mounted

Use Optimum Blade Specification

Lip Effect At Bottom Side

Possible Cause

Affect On Cutting Performance

Solution

Blade not cutting all the way through the material and supporting substrate

Larger Cut Width

Minimize Blade Exposure

Blade Lost ils Ken Edge Form

Process Inconsistency

Adjust the coolant pressure and align the nozzle flow

Uneven Blade Wear

Loss of Productivity

Try Using Larger Blade Diameter

Incorrect Blade Specification

Higher Cutting Costs

Try Using Thicker Kerf Blade

Bond Hardness too Hard

Scarp Parts

Use Correct RPM's

Too High Diamond Concentration

Possible Material Deformation

Reduce Feed Rate

Check Condition of Mounting Flanges

Check Condition of Spindle and its Runout

Make Sure Blade is Properly Mounted

Use Optimum Blade Specification

Asymmetric Chamfer On One Or Both Sides

Possible Cause

Affect On Cutting Performance

Solution

Blade Lost ds Ken Edge Form

Larger Cut Width

Minimize Blade Exposure

Uneven Blade Wear

Process Inconsistency

Adjust the coolant pressure and align the nozzle flow

Incorrect Blade Specification

Loss of Productivity

Try Using Larger Blade Diameter

Bond Hardness too Hard

Higher Cutting Costs

Try Using Thicker Kerf Blade

Too High Diamond Concentration

Use Correct RPM's

Reduce Feed Rate

Check Condition of Mounting Flanges

Check Condition of Spindle and its Runout

Make Sure Blade is Properly Mounted

Use Optimum Blade Specification

Wavy Cut

Possible Cause

Affect On Cutting Performance

Solution

Signs: Uneven, wavy kerf (not starlight cut).

Excessive blade exposure

Possible Chipping

Minimize Blade Exposure

Blade Lost Tension

Larger Cut Width

Adjust the coolant pressure and align the nozzle flow

Spindle Vibration

Not Straight Cut

Try Using Larger Blade Diameter

Incorrect Blade Specification

Process Inconsistency

Try Using Thicker Kerf Blade

Feed Rate too High

Loss of Productivity

Use Correct RPM's

Incorrect RPM's Roo high or too low for the application]

Higher Cutting Costs

Reduce Feed Rate

Insufficient Amount of Coolant Reaching Cutting Zone

Check Condition of Mounting Flanges

Excessive Coolant Veloclt) & Incorrect Nozzle Positioning

Check Condition of Spindle and Its Runout

Make Sure Blade is Properly Mounted

Use Optimum Blade Specification

Try Using Coarser (larger) size diamond crystal

Wider Cut At The Entrance Or Exit Of Cut

Possible Cause

Affect On Cutting Performance

Solution

Signs: Wider kerf at entrance and exit of the cut.

Incorrect feed rate (in and out)

Possible Chipping

User proper feed rate for the application

Spindle vibration

Larger Cut Width

Check condition of spindle and its runout

Not Straight Cut

Process Inconsistency

Loss of Productivity

Higher Cutting Costs

Flange Overtightning

Possible Cause

Affect On Cutting Performance

Solution

Signs: Overnighting the flange cause deflection of the flange, which in turn causes blade wobbing. 

Operator overnight in monitoring the cutting operation

Blade cuts off track(wanders)

User proper torque in not to poor or under tighten the flange

Wide Kerf

Process Inconsistency

Possible flange damage

Possible Chipping

Possible material Deformation

Nick On Flange Edge

Possible Cause

Affect On Cutting Performance

Solution

Signs: Scratch on nick on flange causes improper blade mounting.

Piece of Material Swart! Debris left on inside surface of the flange

Cuts off track (blade wanders)

Check to make sure flanges are flat

Dropping or hitting the Flange while mounting or during use

Wide Kerf

Check to make sure flanges are clean

Failure to periodically clean and maintain the flange

Process Inconsistency

Make sure proper torque not to over or undertighten flanges

Operator overnight In monitoring the cutting operation

Possible blade shattering and breakage

Replace flanges that may damage or worn out

Slanted cuts

More Chipping

Loss On Kerf Edge / Geometry

Possible Cause

Affect On Cutting Performance

Solution

Signs: Loss of Blade Radius.

Incorrect Blade Mounting

Possible Chipping

Check condition of Mounting Flanges

Spindle Run Out

Larger Cut Width

Check condition of spindle and its Runout

Worn Out Spindle

Not Straight Cut

Make sure blade is properly Mounted

Worn Out or Damaged Flanges

Process Inconsistency

Defect on Back Side of Flange

Loss of Productivity

Material Not Correctly Clamped! Fixtured in Vice / Chuck

Higher Cutting Costs

Possible Blade Breakage

Excessive Blade Exposure

Possible Cause

Affect On Cutting Performance

Solution

Signs: Excessive Blade Vibration, not straight cut loss of blade tension and possible blade breakage.

Flange Size to small for the material being cut

Possible Chipping

Adjust the cooling nozzle & the coolant flow

Too High Feed Rate

Possible Blade Breakage

Check me option of using a thicker blade

Incorrect Blade Mounting

Larger Cut Width

Reduce feed rate and f or increase the RPM

Spindle Run Out

Not Straight Cut

Use specialized water soluble coolant

Worn Out Spindle

Short Blade Life

Optimize the blade to minimize loads

Worn Out or Damaged Flanges

Poor Cut Quality / Surface Finish

Use a Lower diamond concentration

Defect on Back Side of Flange

Optimize the diamond size

Material Not Correctly Clamped / Fixtured

Use seraled blades to minimize the loading

Material Moving white Cutting

Improve the mounting method

Incorrect Blade Specification

Slow down the feed rate to minimize the load

Add coolant additives to minimize the load

Material Overheating

Possible Cause

Affect On Cutting Performance

Solution

Signs: Discoloration of the cut surface.

Incorrect Coolant or Mix Ratio Used

Possible Chipping

Optimized the coolant :

  • Align the cooling noozle
  • Optimize the coding flow
  • Use specialized water soluble coolant d possible
  • On deep cuts try a high cooling flange

Inadequate amount of coolant reaching cutting zone

Possible Material Micro Cracking

Use Optimum Blade Specification

Incorrect RPM'S for the Application

Possible Material Deformation

Use Correct RPM's

Too High Feed Rate

Possible Material Change Properties I Structure

Reduce Feed Rate

Incorrect Blade Specification

Material Saw / Vibration

Possible Cause

Affect On Cutting Performance

Solution

Signs: Spindle or Blade Vibration.

Small flange diameter is the largest cause of blade vibration

Possible Chipping

Change Blade tension

Larger Cut Width

Slow Down Feed Rate

Not Straigh Cut

Check Saw Shaft. It may be worn out

Process Inconsistency

Check Flange 'lightness, lack of tightness causes vibration

Loss of productivity

Make sure your saw does not vibrate

Higher Cutting costs

Make sure your material is securely held in place

Make sure your material is securely held in place

When blade speed slows down. proceed to dress

Improper Blade Fixturing /Material Holding

Possible Cause

Affect On Cutting Performance

Solution

Signs: Chipping, Material Breakage & Process Inconsistency.  

Incorrect Material Mounting

Possible Chipping

Make sure your material is securely held in place

Not Supporting Material Underneath

Larger Cut Width

Support Material by bond to Sacrifficial substrate made from glass. ceramic, or graphite

Possible Air Gap from Wax Mounting

Not Straigh Cut

Make Sure there are no air gaps undemeath

Material Moving while Cutting

Process Inconsistency

Use beet material holding method for the material type, shape, and dimensions

Loss of productivity

Higher Cutting costs

Possible Blade Breakage

Blade Gummed Up

Possible Cause

Affect On Cutting Performance

Solution

Signs: Material Swarf Particles Smeared Over Diamond Section of the blade Causing Slower Cutting Speeds, Inconsistent Performance & large variety of possible issues.

Blade not being dressed properly or when needed

Blade Stops Cut-tong

Use Proper Blade Specification

Blade not being dressed properly or when needed

Blade Stops Cutting

Optimized the coolant :

  • Align the cooling noozle
  • Optimize the coding flow
  • Use specialized water soluble coolant d possible
  • On deep cuts try a high cooling flange

Cut