SMART CUT™ Series - 405M

Safety Precautions:

• 1. Personal Protective Equipment (PPE): Always wear appropriate safety gear, including safety shoes, snug-fitting attire, safety goggles, hearing and head protection, and proper respiratory equipment.
• 2. Machine Safety: Always use the blade guards provided with your machine. Do not remove or tamper with any safety devices – they are there for your safety.

Blade Storage:

• 1. When not in use, store the sintered metal bond diamond lapidary blade in a dry and clean environment. Avoid exposure to extreme temperatures, moisture, or direct sunlight.
• 2. Use protective covers or blade guards to prevent accidental damage during storage.
• 3. Keep the blade out of reach of children and unauthorized users.

Before Installation:

• 1. Inspect Machine Shaft: Examine the shaft of your machine for any looseness that might suggest worn bearings. Check for any wear on the shaft itself. Ensure the blade fits securely onto the shaft.
• 2. Examine the Blade:Before mounting, visually inspect the blade for any cracks or signs of damage. Remember, a damaged or improperly mounted blade can be hazardous.
• 3. Check the blade’s rotation direction and ensure it is properly mounted on the saw machine according to the manufacturer’s instructions.
• 4. Make sure the blade is securely fastened to the arbor and that the arbor nut is tightened properly.

Installation:

• 1. Flange Size: Always use a pair of matching flanges, roughly 1/3 the diameter of the blade. Ensure flanges are clean and free of rust or dirt. After tightening the flange nut, the blade should rotate true and even.
• 2. Alignment: For slabbing, ensure accurate carriage alignment to prevent the blade from bending.
• 3. Blade Tracking: Ensure that the blade tracks properly on the saw arbor. Misalignment can lead to uneven wear and reduced blade life. Periodically check and adjust the blade’s alignment as needed.
• 4. Blade Balance: Imbalanced blades can cause vibrations and lead to uneven cuts or equipment wear. To maintain blade balance, periodically check for any accumulated material on the blade body and clean it off.
• 5. Use Proper Size Flanges A pair of the same size flanges with proper relief should be approximately 1/3″ the diameter of the blade. Flanges must be free of rust and dirt. Your blade should turn perfectly rue after flange nut is tightened. Carriage alignment must be accurate for slabbing to prevent bending of the blade.
• 6. Rotate the blade according to Rotation Direction Make sure that arrow on the blade points in the same direction as shaft rotation
• 7. Make Sure Material is Properly Secured Ensure that the material you intend to cut is securely clamped or held in place to prevent it from moving during cutting.

Material Preparation

• 1. Before cutting, inspect the material you intend to work on. Ensure it is free from loose or abrasive particles that could damage the blade or create uneven cuts.
• 2. For large or irregularly shaped materials, consider pre-shaping or trimming them with other tools before using the lapidary blade. This can reduce the stress on the blade and improve cutting precision.

USE RECOMMENDED RPM’S

Best performance and life will result when the blades are operated in the range of 3150 to 500 surface feet per minute. Optimum performance and life will be obtained at the 5000 s.f.m. For your convenience we present the following chart of optimum RPM of shaft for each blade size.

• Adjust the cutting speed and water flow rate according to the material being cut. Softer materials may require slower speeds and less water, while harder materials may require higher speeds and more water.
• When cutting brittle materials like certain types of glass or very hard stones, use a slower blade speed to reduce the chances of cracking or chipping.
• For materials with varying hardness, consider adjusting the blade speed or using a slower feed rate when transitioning from softer to harder areas. This helps maintain a more even cutting surface.

Coolants

• 1. Never run a diamond blade dry. Severe damage will result Coolants do 3 things. They cool your blade and material being cut, clean out the cut being made of abrasive particles, and provide lubrication to keep the cutting edge clean. SMART CUT diamond blades are designed to give you a straight cut in plain water. However, significantly better performance and longer life may be obtained by using water soluble coolant such as SMART CUT coolant or SMART CUT mineral OIL
• 2. Regularly check the water or coolant supply system of your lapidary saw machine. Ensure that the water or coolant flow is consistent and that nozzles are clean and free from blockages.
• 3. Use clean, clear water or coolant in the cooling system to prevent mineral buildup that can clog nozzles and reduce cooling efficiency.
• 4. Periodically inspect and clean the water or coolant reservoir and filter to maintain the quality of the cooling water.

Feed Rates

• 1. Never force a diamond blade Feed material slowly into blade so that the blade doesn’t lead off. Excessive pressure can cause your blade to bend or dish. The rate of feed should never be so great that the blade slows down. Avoid cutting with excessive lateral pressure, which can cause blade warping or damage. Keep the blade’s cutting edge perpendicular to the material being cut.
• 2. Keep an eye on the blade during operation and listen for any unusual sounds. If you notice any vibrations, strange noises, or decreased cutting performance, stop immediately and inspect the blade for damage.
• 3. When cutting materials with embedded crystals like geodes, proceed slowly and carefully to avoid damaging the blade or the crystals.
• 4. Use a continuous and steady feed rate when cutting to maintain a smooth and uniform surface. Avoid rapid or jerky movements, which can lead to uneven cuts.

Blade Dressing

Any diamond blade may occasionally require dressing of the edge to remove surplus metal or glazing to expose new diamond particles. You can dress by making a few cuts in an old 220 grit grinding wheel or a dressing stick made specifically for this purpose. Use coolant with this procedure. The SMART CUT diamond bond is designed to minimize this procedure. By using enough coolant and following the suggested procedures, you can’t rest assured this will require the minimal amount of time as compared to most blades.

Continuously Monitor the Cutting Operation

• Never place your hands or fingers right Next to the Cutting Edge
• Never continue to cut with a damaged blade,one that is dished, bent, flutters, or is not running rue. Continued use will damage the diamonds, pull the matrix out, excessively wear your blade, or cause an accident. If your blade has a tendency to pull to one side, making uneven cuts, reverse the blade. If you still have the same problem, the problem could be the vise alignment If, after reversing, the blade cuts to the opposite side, die blade is bent or dished. If this is the case, the blade must be repaired before further use.
• Most frequent source for blade damage is attempting to cut too large a rock. Maximum material/rock size should be no more than 3/8” of blade diameter.

Blade Cleaning:

• 1. After each use, clean the bladethoroughly to remove any residue, such as mineral buildup or adhesive from previous cuts. Soak the blade in a cleaning solution recommended by the manufacturer, and then use a soft brush to scrub away any stubborn debris.
• 2. Rinse the blade with clean water to ensure all cleaning agents are removed. Pat the blade dry with a clean cloth before storing it.
• 3. Do Not Leave the blade on the arbor or in coolant for long period of time.

Used Coolant Disposal

Disposing of coolant used in lapidary work, such as water or water-based cutting fluids, should be done in an environmentally responsible manner. Follow these steps to properly dispose of coolant after cutting lapidary materials:

1. Containment and Collection:

• Collect the used coolant in a designated container, such as a plastic bucket or drum. Ensure that the container is clean and free from contaminants.
• If there are any solid particles or sediment in the coolant, allow them to settle at the bottom of the container. You can use a settling tank or let the container sit undisturbed for a period to facilitate this process.

2. Separation of Solids:

• After settling, carefully decant or siphon the clear coolant from the container, leaving the settled solids behind. These solids may contain abrasive debris and should not be disposed of down the drain.

3. Recycling or Reuse:

• If the coolant is still in good condition and free from contamination, consider reusing it for further lapidary work. Filter the coolant to remove any remaining suspended particles before reuse
• Some lapidary workshops use a recirculating system that continually filters and treats the coolant for extended use.

3. Recycling or Reuse:

• If the coolant is still in good condition and free from contamination, consider reusing it for further lapidary work. Filter the coolant to remove any remaining suspended particles before reuse
• Some lapidary workshops use a recirculating system that continually filters and treats the coolant for extended use.

4. Dispose of Solids:

• The solids separated from the coolant should be handled as hazardous waste due to potential contamination with abrasive particles and minerals. Check local regulations and guidelines for disposing of hazardous waste in your area.
• In some cases, lapidary workshops collect and dispose of abrasive solids through waste disposal services that specialize in handling hazardous materials.

5. Proper Disposal of Used Coolant:

• The clear, separated coolant can often be disposed of down the drain, especially if it is primarily water-based and does not contain harmful chemicals. However, it’s essential to comply with local, state, and federal regulations regarding wastewater disposal.
• Check with your local municipal or environmental agency for specific guidelines on disposing of used coolant. Some areas may require proper treatment or recycling of wastewater.

6. Neutralization and pH Adjustment:

• If your lapidary work involves the use of acidic or alkaline cutting fluids, it may be necessary to neutralize the coolant before disposal. Neutralization ensures that the pH level of the wastewater is within acceptable limits.
• Consult with a chemical expert or follow recommended guidelines for neutralizing and adjusting the pH of the coolant.

7. Professional Services:

• For lapidary workshops with large volumes of used coolant or those dealing with complex coolant mixtures, consider hiring professional waste management services that specialize in hazardous waste disposal.

Blade Troubleshooting:

• 1. If you encounter excessive chipping or blade wear, it may be due to a mismatch between the blade and the material being cut. Consider using a blade specifically designed for the material’s hardness and composition.
• 2. If the blade starts to wander or deviate from the desired cutting path, it may indicate a misalignment issue. Check the blade’s mounting and alignment, and make necessary adjustments to ensure it runs true.
• 3. Should the blade develop a wobble or vibrations during operation, stop immediately, and inspect for damage or wear. A wobbling blade can be dangerous and should not be used until the issue is resolved.
• 4. In the event of a blade jam or binding, switch off the saw immediately to prevent damage to both the blade and the equipment. Carefully remove the material causing the jam and inspect the blade for any damage before resuming cutting.

Consult our Illustrated Diamond Blade Trouble Shooting Guide which shows all the possible issues people experience when using blades and how to fix and prevent them

Blade Replacement:

• 1. Replace your sintered metal bond diamond lapidary blade when it shows signs of significant wear or damage, such as reduced cutting efficiency, loss of diamond edge, warping/cutting not straight or visible cracks.
• 2. When replacing a blade, follow the saw manufacturer’s instructions for removal and installation. Ensure that the new blade is compatible with your cutting machine.