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SMART CUT® 205M Diamond Sintered Metal Bond Cut Off Blades are meticulously engineered for ultra hard and brittle materials. These blades offer unmatched accuracy, fast cutting speed, precision and durability, making them an essential for large variety advanced ceramics, composites, optics, and many other materials.
SMART CUT® 205M blades feature a high concentration of premium-quality diamonds impregnated inside of soft bond metal bond matrix. This design ensures a smooth, swift cutting action, prolonged blade life, and minimal amount stress to material being cut.
Ultra Hard Materials such as sapphire, silicon carbide, boron nitride, alumina oxide, yag and other similar materials are very hard to cut and not many blades are able to provide the right combination of cutting speed, surface finish and life. This is why SMART CUT® 205M Blades stand out from the rest.
SMART CUT 205M Blades are ideal for a wide range of applications involving ultra-hard and dense materials, including but not limited to:
SMART CUT 205M Diamond Sintered Metal Bond Cut Off Blades are designed to cut a wide range of ultra-hard and dense materials, including, but not limited to:
These blades excel in providing precise cuts on materials that are notoriously difficult to machine with conventional cutting tools.
Yes, SMART CUT 205M Blades can be used for wet cutting applications. SMART CUT water soluble coolant and other suitable coolants/lubricants can be employed to reduce heat generation, minimize dust, and extend the blade’s lifespan during cutting. Wet cutting also helps maintain the integrity of the material being processed.
Yes, safety is paramount when using any cutting tools. Some safety precautions to consider when using SMART CUT 205M Blades include:
Always prioritize safety to prevent accidents and ensure a successful cutting operation.
SMART CUT 205M Blades are versatile and can be used with various types of cutting machinery, including precision saws, CNC machines, and other equipment designed for cutting hard materials. It’s important to ensure that the blade’s arbor size is compatible with the machinery you plan to use.
SMART CUT 205M Blades are designed to have a long lifespan, but they are typically not re-sharpened or reconditioned. Once the diamonds in the blade matrix wear down, it’s more cost-effective to replace the blade with a new one to maintain cutting performance.
To maintain the performance and longevity of SMART CUT 205M Blades during use, it is advisable to:
Regular inspection and maintenance will help maximize the lifespan and cutting efficiency of the blades.
Yes, SMART CUT 205M Blades are versatile and suitable for both laboratory research and industrial applications. They are commonly used in materials science research, aerospace, precision machining, and other industries that require cutting of ultra-hard and brittle materials.
If you have specific questions about using these blades in your laboratory or industrial setting, please feel free to reach out to our technical support team for further assistance.
SMART CUT 205M Blades are designed to minimize chipping and micro-cracking in the cut material, especially when used with the appropriate cutting parameters and techniques. However, the extent of chipping or micro-cracking may still depend on the material being cut, its inherent properties, and the specific cutting conditions. It’s advisable to perform test cuts and optimize cutting parameters to achieve the best results for your application.
The recommended procedure for mounting SMART CUT 205M Blades onto cutting equipment may vary depending on the specific equipment and manufacturer’s instructions. However, in general, it involves securely attaching the blade to the machine’s arbor or spindle, ensuring proper alignment and tightening to prevent blade wobble. Always follow the equipment manufacturer’s guidelines and safety precautions when mounting the blade.
In laboratory settings or cleanroom environments, it’s essential to maintain a clean and controlled workspace. Specific safety precautions may include:
Always adhere to the cleanliness and safety standards of the specific laboratory or cleanroom environment where you intend to use SMART CUT 205M Blades.
When cutting highly abrasive materials, such as composites with abrasive fillers, it’s important to be aware that the abrasive nature of the material can impact blade wear. Consider the following:
Properly maintaining and inspecting the blade during and after cutting abrasive materials will help ensure its longevity and performance.
Handling SMART CUT 205M Blades safely is crucial to prevent accidents and ensure operator safety. Some recommended safety precautions include:
Always prioritize safety when handling SMART CUT 205M Blades.
SMART CUT 205M Blades are primarily designed for cutting ultra-hard and brittle materials. While they can be used for cutting materials with high thermal conductivity, it’s important to consider the specific cutting conditions and parameters to manage heat generation effectively. Using appropriate cooling methods and adjusting cutting parameters may be necessary to ensure the integrity of the cut and minimize blade wear.
Yes, SMART CUT 205M Blades can be used for both wet and dry cutting of materials with varying hardness. The choice between wet and dry cutting depends on the specific material, the desired cut quality, and other factors. Wet cutting with water or a suitable coolant is often preferred to control heat, reduce dust, and extend blade life. Dry cutting may be suitable for certain applications, but it’s essential to adjust cutting parameters accordingly.
When cutting materials that are prone to chemical reactions with water or coolants, it’s important to choose an appropriate coolant that will not react with the material being cut. Some materials, such as certain metals or chemicals, may require specialized cutting techniques or dry cutting to avoid chemical reactions. Always consider the compatibility of the material and the coolant to ensure safe and effective cutting.
SMART CUT 205M Blades can be used for cutting materials with impurities or contaminants, but it’s important to be aware that these impurities can affect blade wear and cutting performance. Depending on the nature of the impurities, they may lead to increased blade wear or other challenges during cutting. It’s advisable to monitor blade wear more closely and consider appropriate cleaning methods to maintain cutting efficiency when working with impure materials.
SMART CUT 205M Blades can be used for cutting composite materials with multiple layers of different hardness or composition. Their precision and versatility make them suitable for such applications. However, it’s important to optimize cutting parameters and take into account the variations in hardness and composition to achieve clean and accurate cuts through each layer.
SMART CUT 205M Blades can be used for cutting composite materials with embedded reinforcements like carbon fibers or metal fibers. However, the presence of these reinforcements can affect blade wear and cutting performance. It’s important to consider the nature and distribution of the reinforcements and optimize cutting parameters accordingly. Test cuts may be necessary to determine the most effective cutting approach.
Yes, SMART CUT 205M Blades can be used for cutting materials with layered structures, such as laminates or semiconductor wafers. Their precision and ability to maintain a smooth cutting action make them suitable for applications where clean, accurate cuts through layered materials are required. Properly optimizing cutting parameters is important for achieving high-quality results.
SMART CUT 205M Blades can be used for cutting highly reflective materials, but precautions should be taken to minimize potential reflections or glare. Proper lighting and safety measures should be in place to ensure the safety of the operator. Additionally, using appropriate coolant or lubrication can help manage heat generation and maintain cutting performance when working with reflective materials.
Yes, SMART CUT 205M Blades are well-suited for cutting highly brittle materials like ceramics and glass. Their design minimizes stress on the material, reducing the risk of fracturing during cutting. However, it’s important to optimize cutting parameters, such as feed rate and speed, to prevent excessive pressure on the material and ensure clean cuts.
Yes, SMART CUT 205M Blades are compatible with automated cutting systems, including CNC machines. Their precision and durability make them suitable for high-precision and repeatable cutting tasks. These blades can be used in conjunction with automated systems to achieve consistent and accurate results in various applications.
SMART CUT 205M Blades are suitable for cutting materials with stringent surface finish requirements, such as optical components or semiconductor wafers. Their ability to provide smooth and precise cuts makes them well-suited for applications where a high-quality surface finish is essential. Properly optimizing cutting parameters and using appropriate coolants or lubrication is important to achieve the desired surface finish.
Yes, SMART CUT 205M Blades can be used for cutting materials with complex geometries, including multi-faceted gemstones and intricate semiconductor packages. Their versatility allows for precise cuts and intricate shapes to be achieved. When cutting materials with complex geometries, it’s important to plan the cutting path and optimize cutting parameters to ensure accuracy.
SMART CUT 205M Blades can be used for cutting materials that require minimal post-processing. Their ability to provide clean and precise cuts reduces the need for extensive post-cutting finishing work. However, the extent of post-processing required may still depend on the specific material and application. It’s advisable to assess the finished cut and make any necessary adjustments to meet the desired specifications.
SMART CUT 205M Blades are compatible with a range of cutting speeds, allowing for adjustments based on material characteristics and cutting requirements. The ability to vary cutting speed makes these blades versatile and adaptable to different materials and cutting conditions. It’s important to consult the manufacturer’s guidelines and perform test cuts to determine the optimal cutting speed for your specific application.
SMART CUT 205M Blades can be used for cutting materials with high thermal expansion coefficients, but it’s important to consider potential thermal effects during cutting. High thermal expansion materials can expand and contract during the cutting process, affecting the precision of the cut. Using appropriate cooling methods and optimizing cutting parameters can help mitigate the impact of thermal expansion and maintain cutting accuracy.
SMART CUT 205M Blades can be used for cutting materials with stringent flatness requirements, such as precision optics or semiconductor wafers. Their precision and ability to provide smooth, accurate cuts contribute to achieving the desired flatness. Properly optimizing cutting parameters and ensuring the equipment is well-maintained are important factors in meeting flatness specifications.
Yes, SMART CUT 205M Blades can be used for cutting materials with complex layer structures, including multilayer ceramics and advanced electronic components. Their versatility allows for precise cuts through different layers, provided that the cutting parameters are adjusted to accommodate variations in material properties and layer composition.
When cutting materials that are highly sensitive to vibration, it’s important to minimize vibrations during the cutting process. SMART CUT 205M Blades are designed to provide smooth and precise cuts, but vibrations can still occur, especially at high cutting speeds. Using stable cutting equipment, ensuring proper blade installation, and reducing cutting forces by optimizing parameters can help minimize vibrations and protect sensitive devices or instruments.
SMART CUT 205M Blades are engineered to minimize edge chipping when cutting brittle materials like glass or ceramics. Their design reduces stress on the material, helping to reduce the risk of edge chipping. However, it’s essential to optimize cutting parameters and handle the material carefully to further minimize the potential for edge chipping.
SMART CUT 205M Blades can be used for cutting materials that are highly porous, but it’s important to be aware that the porous nature of the material can affect blade wear and cutting performance. Porous materials may require adjustments to cutting parameters and may generate more dust or debris during cutting. Properly maintaining and inspecting the blade during and after cutting is essential when working with porous materials.
SMART CUT 205M Blades can be used for cutting materials with stringent dimensional tolerances, such as critical aerospace components or medical devices. Their precision and ability to provide accurate cuts make them suitable for applications where precise dimensions are crucial. Properly optimizing cutting parameters and carefully monitoring the cutting process are essential for meeting dimensional tolerances.
SMART CUT 205M Blades are primarily designed for cutting non-metallic and ultra-hard materials. While they can be used for some non-ferrous materials, they may not be suitable for highly magnetic materials. Highly magnetic materials may require specialized cutting tools designed to handle magnetic properties without affecting the cutting process. Consider alternative cutting methods or tools for such materials.
SMART CUT 205M Blades are compatible with a wide range of cutting machines, including precision saws, CNC machines, and other cutting equipment designed for diamond blade use. These blades can be integrated into various cutting setups to suit your specific application.
The recommended RPMs for SMART CUT 205M Blades can vary depending on the blade diameter and the specific material being cut. In general, a range of 1,000 to 4,000 RPM is commonly used as a starting point. However, it’s crucial to consult the our guidelines and perform test cuts to determine the optimal RPMs for your specific application.
When using SMART CUT 205M Blades, it is recommended to use coolants to dissipate heat generated during cutting. Water-based coolants or specialized cutting fluids are commonly used. Coolants help reduce friction, control heat, and minimize the risk of thermal damage to both the material being cut and the blade. They also help in reducing dust and extending blade life.
When using SMART CUT 205M Blades, you can expect a high-quality surface finish. These blades are designed to provide smooth and precise cuts, which contribute to achieving a fine surface finish. The exact finish can vary based on the material being cut and the cutting parameters, but they are generally capable of meeting stringent surface finish requirements.
SMART CUT 205M Blades are engineered to minimize chipping during cutting, especially in brittle materials like ceramics and glass. When used with appropriate cutting parameters and techniques, you can expect minimal to no visible chipping. However, the level of chipping may still depend on the material’s properties and the care taken during the cutting process. Proper optimization and testing can help achieve the desired results.
Please note that the specific RPM, coolant, feed rate, surface finish, and chipping levels may vary depending on the material being cut and the equipment used. Always refer to the manufacturer’s guidelines and perform test cuts to fine-tune these parameters for your unique application.
Yes, optimizing cutting parameters is essential for achieving the best results when using SMART CUT 205M Blades on different materials. Here are some general guidelines:
SMART CUT 205M Blades can be used for dry cutting applications, but there are important considerations:
Achieving the desired surface finish and minimizing chipping involves fine-tuning cutting parameters:
SMART CUT 205M Blades can be used for materials with varying hardness within the same application. To adjust cutting parameters:
When cutting materials with complex layer structures:
When cutting vibration-sensitive materials:
When cutting highly porous materials:
To meet stringent flatness requirements:
SMART CUT 205M Blades are primarily designed for non-metallic and ultra-hard materials. They may not be suitable for highly magnetic materials. For cutting highly magnetic materials, consider alternative cutting tools designed to handle magnetic properties without affecting the cutting process. Magnetic materials often require specialized cutting techniques and tools.
When cutting highly reflective materials:
Consider using anti-reflective coatings or specialized techniques to reduce reflections during cutting.
SMART CUT 205M Blades can be used for temperature-sensitive materials, but temperature control is crucial:
Optimizing cutting parameters is essential to achieve the best results when working with various materials and applications. Always consider the specific characteristics and requirements of the material being cut, and be prepared to perform test cuts to fine-tune parameters accordingly.
Achieving precise dimensional tolerances requires careful optimization of cutting parameters:
SMART CUT 205M Blades can be used for materials with high thermal expansion coefficients, but consider these factors:
SMART CUT 205M Blades can help minimize post-processing requirements:
SMART CUT 205M Blades can be used for both wet and dry cutting:
For materials reactive with water or coolants:
Blade dressing is essential for maintaining the performance of SMART CUT 205M Blades. The frequency of dressing depends on several factors, including the material being cut, cutting parameters, and blade wear. Here’s more information:
Blade dressing is the process of exposing new diamond abrasive particles on the blade’s cutting edge. Over time, diamond blades can wear, leading to reduced cutting efficiency and quality. Dressing helps restore the blade’s sharpness and cutting effectiveness.
Several indicators suggest it’s time to dress the blade:
Several factors influence how often you should dress SMART CUT 205M Blades:
Blade quality: Blade quality and initial sharpness affect wear rates.
Blade dressing can be done using a dressing stick or dressing tool designed for diamond blades. The process typically involves running the dressing tool against the rotating blade to expose new diamond abrasive particles. Follow the manufacturer’s guidelines for dressing procedures and use appropriate safety equipment.
When dressing the blades, take these precautions:
SMART CUT 205M Blades can be dressed multiple times to extend their lifespan. However, there are limitations to how many times a blade can be dressed, as excessive dressing can reduce blade life. The number of dressings a blade can withstand depends on factors like blade quality and initial sharpness.
Dressing SMART CUT 205M Blades can be done in-house if you have the necessary equipment and follow manufacturer guidelines. However, if you’re unsure or inexperienced, it’s advisable to consult a professional or the blade manufacturer for guidance to ensure proper dressing and blade maintenance.
The dressing process can vary based on the material being cut and the application. Consult the blade manufacturer’s guidelines for specific recommendations on dressing SMART CUT 205M Blades for different materials or applications. Tailoring the dressing process to the material and application can help maximize blade performance.
Regular blade dressing is essential for maintaining the cutting effectiveness and longevity of SMART CUT 205M Blades. By monitoring wear indicators and following proper dressing procedures, you can ensure consistent cutting performance and quality results.
Neglecting to dress SMART CUT 205M Blades regularly can lead to several undesirable consequences:
Over-dressing SMART CUT 205M Blades can have adverse effects, including excessive diamond particle removal and reduced blade life. To avoid over-dressing, follow these guidelines:
The frequency of dressing SMART CUT 205M Blades is highly dependent on the specific application, material, and cutting parameters. While there’s no one-size-fits-all rule, a good practice is to monitor the blade’s performance regularly. When you observe signs of reduced cutting efficiency, poor surface finish, or other wear indicators, consider dressing the blade. Keep records of blade performance to establish a maintenance schedule tailored to your specific needs.
Blade dressing can be integrated into routine blade maintenance. Performing regular inspections and dressing when needed can help prevent excessive wear and maintain consistent cutting performance. Incorporating blade dressing into your maintenance schedule can contribute to longer blade life and better cutting results.
Advanced techniques and tools for dressing SMART CUT 205M Blades can enhance the dressing process and extend blade life. These may include:
Consulting with blade manufacturers for customized dressing solutions based on your application needs.
SMART CUT 205M Blades can be re-dressed to restore some of their original sharpness and cutting effectiveness. However, there is a limit to how much they can be restored, as the diamond abrasive particles wear down over time. Blade quality, initial sharpness, and the number of previous dressings can influence how effectively a blade can be restored. Eventually, when the diamond particles are too worn, the blade may need replacement.
When dressing SMART CUT 205M Blades for highly abrasive materials:
Blade dressing can be performed on-site if you have the necessary equipment and expertise. However, if you’re uncertain or prefer professional handling, you can send blades to specialized services for dressing and maintenance. These services often have specialized tools and experience to ensure effective blade dressing and prolong blade life.
Image | Name | COMPATIBILITY WITH DRILL SERIES | Price | Quantity | Add to cart |
|---|---|---|---|---|---|
 | Recommended for use in Diamond Tools 150 Grit Size (mesh… | $15.39 | Max: Min: 1 Step: 1 | ||
 | Recommended for coarser grits found in segment wheels, core drills… | $15.99 | Max: Min: 1 Step: 1 | ||
 | 5/8″-11″ thread. Fits into drill press chuck. Shank adapter threads… | $22.46 | Max: Min: 1 Step: 1 | ||
| 5/8″-11″ thread. Fits into drill press chuck. Shank adapter threads… | $26.72 | Max: Min: 1 Step: 1 | ||
 | SMART CUT® General Materials Formula Synthetic Water Soluble Coolant | $34.81 | Max: Min: 1 Step: 1 | ||
 | Recommended for use in Diamond Tools 150 Grit Size (mesh… | $39.47 | Max: Min: 1 Step: 1 | ||
 | Recommended for coarser grits found in segment wheels, core drills… | $39.47 | Max: Min: 1 Step: 1 | ||
 | SMART CUT® General Materials Formula Synthetic Water Soluble Coolant | $99.81 | Max: Min: 1 Step: 1 | ||
 | 105DE, 135DB, 115DM, 125DM, 130DMN, 140DM (up to 1-5/8″ OD) | $154.87 | Max: Min: 1 Step: 1 | ||
 | 105DE, 135DB, 115DM, 125DM, 130DMN, 140DM (up to 1-5/8″ OD) | $154.87 | Max: Min: 1 Step: 1 | ||
 |
105DE, 135DB, 115DM, 125DM, 130DMN, 140DM (up to 1-5/8″ OD) | $235.00 | Max: Min: 1 Step: 1 | ||
 | SMART CUT® General Materials Formula Synthetic Water Soluble Coolant | $317.41 | Max: Min: 1 Step: 1 | ||
 | SMART CUT® General Materials Formula Synthetic Water Soluble Coolant | $1,745.00 | Max: Min: 1 Step: 1 |
3106008, 3128206, 3148202, 3168201
Image | New Item No: | Outside Diameter | Kerf Thickness | Arbor Size / Inside Diameter | Price | Quantity | Add To Cart |
|---|---|---|---|---|---|---|---|
 | 10” | .060" | 1.25” 32mm | $190.00 | Max: Min: 1 Step: 1 | ||
| 12" | .082" | 1.25” 32mm | $275.00 | Max: Min: 1 Step: 1 | ||
| 14" | .082" | 1.25” 32mm | $295.00 | Max: Min: 1 Step: 1 | ||
| 16" | .082" | 1.25” 32mm | $325.00 | Max: Min: 1 Step: 1 |
Sintered (metal bonded) diamond tools have multiple layers of diamonds impregnated inside the metal matrix. Diamonds are furnaces sintered in a matrix made of iron, cobalt, nickel, bronze, copper, tungsten, alloys of these powders or other metals in various combinations. Metal bonded diamond tools are “impregnated” with diamonds. This means that selected diamonds are mixed and sintered with specific metal alloys to achieve the best cutting performance possible on any materials such as sapphire, advanced ceramics, optics, glass, granite, tile and etc. The metal bond surrounding the diamonds must wear away to continuously keep re-exposing the diamonds for the diamond tool to continue cutting. Sintered (metal bonded) diamond tools are recommended for machining hard materials from 45 to 75 on rockwell scale (5 to 9.5 on mohe’s scale of hardness).
The newly exposed diamonds don’t effect diamonds already working on the material. Unlike many other diamond bonds, diamonds in a SMART CUT® Bond remains sharp and grow sharper with each cut, prolonging product life and consistent performance.
Diamonds or CBN Crystals are activated only at the exposed layer. As Bond Matrix layer begin to wear out, diamonds in a new Bond Matrix layer are immediately activated, substituting the already used up diamond layer. The SMART CUT® Diamond Hybrid Bond makes sure every diamond is in the right place and at the right time, working where you need it most.
This advanced formulated open diamond bond design insures minimal chipping, fast cut, constant speed of cut, minimal cutting noise, and most important of all, consistent performance.
Diamond & CBN blades with SMART CUT® technology require minimum dressing, the bond renews itself.
SMART CUT® blades made utilizing SMART CUT® technology are much more aggressive then conventionally blades. They can cut faster, while still leaving behind a smooth surface finish.
SMART CUT® Series Sintered (metal bond) blades are the best investment you can make! Although they may cost more than other sintered (metal bond), blades. Designed for users that understand and appreciate quality. They will more than pay for themselves in terms of overall performance and provide best Return on Investment.
Only the highest quality synthetic diamonds and raw materials are used in the manufacturing process. The highest quality standards and product consistency is maintained, using sophisticated inspection and measurement equipment.
Diamond Concentration – Diamond Concentration is still a factor in determining the life and cutting speed of your Diamond Cut off Wheels / Blades.
High diamond concentration helps enhance the longevity of the blade by distributing the cutting workload across more diamonds, reducing wear on individual diamonds and extending the blade's overall life. This setup results in a smoother finish since more cutting points engage with the material simultaneously, which is crucial for materials requiring a high-quality finish like optical materials or precision ceramics.
With more diamonds embedded in the resin matrix, these blades maintain their cutting capability longer, ensuring consistent performance throughout their lifespan. This is vital for applications needing uniform cuts in serial production or where precise dimensional tolerances are critical. Although resin bonds inherently generate less heat, the increased number of cutting points with high diamond concentration disperses the friction-generated heat more evenly, further reducing the risk of thermal damage to sensitive materials.
Low concentration resin bond diamond cut off blades and wheels provide several advantages, especially suited for cutting hard and brittle materials like ceramics, glass, or sapphire. With fewer diamonds embedded in the resin matrix, each diamond can exert more force on the material, enhancing precision and minimizing material deformation. This setup also reduces the risk of removing too much material too quickly, which is vital in applications requiring high precision and minimal kerf.
The increased spacing between the diamonds allows for better chip formation and removal, preventing the accumulation of debris that can affect cutting quality and increase the risk of blade overheating. Additionally, fewer diamonds mean less friction during cutting, which results in decreased heat generation. This is crucial when working with materials sensitive to thermal damage, such as those that might warp or undergo microstructural changes.
For resin bond diamond cut off blades and wheels, blade thickness plays a critical role in determining the amount of material removed during the cutting process, which is referred to as the kerf. The kerf size increases in proportion to the blade diameter, and it represents the width of the material that is removed as the blade passes through the sample. Choosing the correct blade thickness is essential for minimizing material loss, while insuring blade stability and cut quality.
For applications demanding high precision, thinner and smaller diameter blades are preferable. Blades ranging from 3 inches to 6 inches (75mm to 150mm) in diameter with a thickness of 0.015 inches to .020” thickness (0.4mm to 0.5mm) are typically best suited for these purposes. The optimal blade thickness for a particular material or application depends on various factors, including the cutting equipment used on, desired cutting speed, load or feed rate, material diameter, thickness, hardness, density, and shape, as well as the skill and experience of the operator.
Thicker resin bond diamond cut off blades offer increased stiffness and can withstand higher loads and feed rates. Another advantage of a thicker kerf is that it is more forgiving to operator error and misuse. This makes thicker kerf blades particularly recommended for environments where equipment is shared among a large number of individuals, They are ideal for less experienced or novice saw operators, providing a safer and more forgiving use-case scenario.
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The diamond particle or grit size in resin bond diamond cut off wheels plays a an important role in how they perform across various cutting parameters such as cutting speed, surface finish, & blade life. Larger, coarser diamond particles allow the wheel to cut through material more quickly, improving time efficiency and increase blade life. However, this comes with a trade-off as coarser diamonds can increase microstructural damage to the material due to their aggressive cutting action.
On the other hand, finer diamond grits contribute to a superior surface finish and higher quality cut. These smaller particles make less aggressive cuts, and produce better surface finish with minimal to no chipping on edges of material. Additionally, finer diamonds ideal for cutting fragile or delicate materials where maintaining the material's integrity is essential.
Choosing the right diamond grit size is key for optimizing the cutting process with resin bond diamond cut off wheels. For delicate or brittle materials, finer diamond grits are preferable to minimize chipping and microstructural damage while ensuring a high-quality surface finish. In scenarios where cutting speed is a priority and the material can tolerate more aggressive cutting, coarser diamond grits might be more suitable.
Coarse Diamond Grit Size, ranging from 60 to 100 mesh, are typically for cutting large variety of hard materials such as tungsten carbide, metals, and some ultra hard ceramics such as boron nitride and silicon carbide.
Medium Diamond Grit Sizes, As grit sizes become slightly finer, in the 120 to 200 mesh range labeled as medium, these are more commonly used for most resin bond diamond cut off blade / wheel applications such as cutting most types of glass, ceramics, optical glass, and other ultra hard and brittle materials
Fine grit size, which span from 229 to 320 mesh, designed for providing smoothest surface finish and minimal amount of chipping possible. These sizes are usually used for cutting quartz, Pyrex, fragile crystals and other fragile materials
Resin bond diamond cut off blades are renowned for their exceptional cut quality, surpassing that of any other type of diamond blade available. They are specifically recommended for applications where the quality of the cut and the surface finish are paramount. This superior performance is particularly evident when compared to sintered (metal bond) blades, which, while durable, do not typically match the precision and smoothness provided by resin bond blades.
Resin bond blades use a composite material in which diamond particles are embedded in a resin matrix. This configuration allows for a smoother interaction with the material being cut, resulting in cleaner cuts with minimal chipping and superior surface finishes. The flexibility of the resin bond also enables a finer control over the cutting process, which is crucial in applications requiring high precision, such as in the fabrication of intricate components in the electronics and aerospace industries.
Furthermore, the unique properties of resin bond blades allow them to deliver excellent performance on a wide range of materials, including hard, brittle substances like glass, ceramics, and semiconductor materials.
These diameters are carefully chosen based on the specific needs of the application, the properties of the material being cut, and the capabilities of the cutting machine. Resin diamond cut off blades & cutoff wheels, which are available in sizes ranging from 1 inch to 20 inches in diameter, offer varied capabilities based on their size. The diameter of the blade should be chosen with consideration to the diameter and thickness of the material being cut. Smaller diameter blades, which tend to be thinner, are more susceptible to bending and warping during use. On the other hand, larger diameter blades, being thicker, provide greater stability and are typically employed for cutting larger and heavier materials. These larger blades can handle higher loads and speeds, making them suitable for more demanding cutting tasks.
Feed rates for resin bond diamond cut off blades in tile saws and precision cutting saws are critical to the cutting performance and quality of the final cut, and these rates must be adjusted to achieve desired objectives
For harder materials such as ceramics and metals, a faster feed rate may be necessary to efficiently cut through the material. This requires careful handling to ensure the blade does not overheat or wear prematurely. On the other hand, brittle materials like silicon, often used in precision applications, benefit from a slower feed rate to prevent chipping or cracking.
The optimal feed rate is also influenced by the speeds or RPMs at which the blade operates. Higher speeds can allow for quicker cuts but might increase the risk of damage to sensitive materials. Additionally, the geometry and size of the material, along with how securely it is held in place, are important considerations. Proper clamping of the material minimizes movement and vibration, enhancing the blade's effectiveness and the quality of the cut. Adjusting the feed rate manually requires a careful balance of these factors
In resin bond diamond cut off blades, the hardness of the bond matrix significantly influences its ability to retain diamond particles and impacts the overall performance of the blade. As the bond hardness increases, the retention of diamonds improves, which can enhance the blade's durability but may result in a slower cutting speed. Blades with harder bond matrices generally exhibit a longer lifespan due to this increased retention.
Resin bond diamond cut off blades are classified according to their bond hardness, with designations ranging from Soft, Medium, to Hard, and numerous variations within these categories based on the degree of hardness or softness.
Selecting a blade with the optimum bond hardness is critical for achieving efficient and precise diamond sawing operations. A bond matrix that is too soft for the material being cut tends to release diamond particles prematurely, leading to rapid wear and a reduced lifespan of the blade. Conversely, a bond matrix that is too hard can significantly slow down the cutting process and necessitate frequent dressing to expose new layers of diamond.
For cutting harder materials like sapphire and alumina, softer bonds are typically preferred because they allow for easier diamond exposure and faster cutting, essential for maintaining efficiency without damaging the blade. For softer and more brittle materials, harder bonds are advantageous as they ensure better diamond retention, reducing the frequency of blade replacements and maintaining consistent performance.
Resin bond diamond cut off wheels are usually used at higher speeds then sintered (metal bond) Resin bond diamond blades are usually used on manual saws such as tile saws and precision cut off saws, it’s essential to select the right RPM range to ensure optimal cutting performance and to maintain the integrity of the material. Tile saws and other lower-powered manual saws typically operate at RPMs up to 5,000, which is suitable for cutting large variety of materials such as glass.
In contrast, precision manual and automatic cut off saws, which handle a wider variety of materials and more complex cutting tasks, can accommodate a broader RPM spectrum. These saws might operate at speeds up to 100 to 6,000 RPMs.. The higher speeds enable efficient cutting of dense materials, whereas lower speeds are preferable for brittle materials such as advanced ceramics.Adjusting the blade speed according to the material properties, from the hardness to the brittleness, is critical.
Diamond Concentration is still a factor in determining the life and cutting speed of your Diamond Sectioning/Wafering Blade. Higher diamond concentration is recommended and usually used for cutting softer and more abrasive types of materials. However, the trade off is significantly slower cutting speed. Low diamond concentration is recommended and widely used for cutting ultra hard and brittle materials.
Low Diamond Concentration - Typically low concentration wafering blades should be for cutting ultra hard and brittle materials such as ceramics and glass. In Low Concentration Wafering Blades, diamond works by fracture process. Pressure on each diamond crystal/particle is higher which provides enough stress to chip off small flakes in the cut.
High Diamond Concentration - High concentration diamond wafering blades are recommended for cutting metals, plastics and polymers. In this application, materials cut by a plowing mechanism. In this applications diamond plough through the material, work hardened strips of materials become brittle and break off. The greater number of diamond by volume, the quicker the cutting action will be. Increasing the number of diamond s also lowers the per unit force. For metals where it is possible to induce deep deformation layers, a lower per unit force is desirable to reduce the deformation during the cut.
Diamond Mesh Size plays a major role in determining your cutting speed, cut quality/surface finish, level of chipping you will obtain, and material microstructure damage you will obtain. Diamond Mesh size does have considerable effect on cutting speed. Coarse Diamonds are larger than finer diamonds and will cut faster. However, the tradeoff is increase in material micro damage. If you are cutting fragile, more delicate materials then finer mesh size diamond wafering blades are recommended.
Wafering blade thickness typically ranges from .006” to .040” (1mm). Thinner and thicker wafering blade are available, frequently from stock upon request. Kef thickness typically increases with blade diameter (in proportion to diameter of the blade). Kerf is the amount of material removed from the material/sample due to the thickness of blade passing though the material/sample. Blade thickness is important for users requiring most minimal amount of material loss during sectioning. For example if the user requires precision position of the cutting plane relative to the detail on the sample (IC circuit for example), a thinner and smaller diameter blade would be best for this application. Blades ranging from 3” to 5” (75mm to 125mm) in diameter and thickness .006” to .015” (0.2mm to 0.4mm) would be bet suited for this purpose. There are large variety of factors that will contribute to optimal blade thickness for your material/application Including your desired cutting speed, load/feed rate, material diameter, thickness, hardness, density, and shape. As well as skill & experience of the operator. Thicker wafering blades are more stiff and can whistand higher loads/feed rates. Another advantage of thicker kerf blades is they are more forgiving to operator error and abuse. Thicker kerf blade are recommended for use in environment where large number of individuals will be sharing and using same equipment. Perfect for less experienced and novice saw operators, such as in University laboratory.
Typically wafering blade diameters range form 3” (75mm) to 8” (200mm). Wafering blade diameter should be selected based on material diameter and thickness being cut. Smaller diameter wafering blades are thinner than the larger diameter blades and are more prone to bending and warping. Although large diameter blades are thicker, they are typically used for cutting larger and heavier samples at higher loads and speeds than smaller blades.
Ability of the bond matrix to hold diamonds. As the hardness of the bond is increased, its diamond retention capabilities increase as well. However the trade off is slower cutting speed. Life of the diamond blade is usually increased with hardness of its bond matrix. Bonds are designated on their scale of hardness from Soft, Medium, and Hard. There are dozens of variations and classification schemes based on bond degree of hardness or softness. Using diamond blades with optimum bond hardness for your application is important to successful precision diamond sawing operation. Bond matrix that is too soft for the material being cut will release diamond particles faster than needed, resulting in faster wear and shorter diamond blade life. On other hand bond matrix that is too hard will result in much slower cutting speeds and require constant dressing to expose the next diamond layer. As rule of thumb, harder materials such as sapphire and alumina generally require a softer bond. Whereas softer and more brittle materials require a harder bond.
Metal bonding offers long life and durability, while resin bonding creates less heat, provides better surface finish and is well suited for cutting hard, delicate or brittle materials.
Load/Feed Rate applied to wafering blades typically vary from 10-1000 grams. Generally, harder specimens are cut at higher loads and speeds (e.g. ceramics and minerals) and more brittle specimens are cut at lower loads and speeds (e.g. electronic silicon substrates). The Speeds/RPM’s you are using, shape/geometry of the specimen, and how the specimen is being clamped/hold in place will affect the load that can be used for your application.
Most wafering blades are used between 50 to 6,000 RPM’s Typically harder and more denser materials such as Silicon Carbide, are cut at higher RPM’s/speeds Where more brittle materials such as silicon wafers and gallium arsenide are cutting at lower RPM’s. Low Speed saws RPM’s are typically limited from 0 to 600 RPM’s. Where high speed saws offer much large variety of cutting speeds from 0 to 6,000 RPM’s.
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UKAM Industrial Superhard Tools is a U.S. High Technology, Specialty Diamond Tool & Equipment manufacturer. We specialize in producing ultra thin & high precision cutting blades and precision cutting machines diamond drills, diamond micro tools, standard & custom advanced industrial diamond tools and consumables.
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