Diamond discsis a tool for cutting and grinding hard materials due to the abrasive layer of synthetic diamond grit. The tool significantly outperforms conventional abrasive wheels in terms of resource, accuracy and processing speed. In addition, during operation, the diameter of the disk, and, accordingly, the linear speed of rotation and the depth of cut, practically do not change. Therefore, diamond wheels are optimally suited for work in large volumes.
Features of the manufacture of discs
The diamond disc is a circle of high-strength steel, on the edge of which diamond chips are applied, forming a cutting part. The chips are obtained by grinding artificial diamond crystals to a size of 400–600 microns. The resulting powder is combined with a binder, for example, cobalt, which secures the diamond particles on the disk, and is pressed into blanks of cutting segments by cold or hot pressing, or electrolysis methods, high-temperature solder are used to apply diamond grit directly to the metal surface of the disk. discs withsilver solderingDesigned for wet cutting of materials, they are mainly used on stationary machines.laser weldingcontributes to the greatest strength of the connection. These discs allow you to perform both dry and wet cutting of any materials.sinteringused for diamond discs of small diameter, such circles have an increased resource. In addition, there isgalvanic method(electrolysis), in which the diamond layer is applied without a binder directly to the metal, including the side surfaces of the disk. The method is also usedhigh temperature vacuum brazingin which a composition is applied to the disc body, which includes diamond crystals, and then the composition is melted in a vacuum furnace and soldered with crystals into the disc body. Thus, the main technologies in the production of diamond discs can be distinguished:
- silver soldering;
- laser welding;
- cold pressing;
- hot pressing;
- high temperature vacuum soldering.
Diamond blades are suitable for installation on the following equipment:
- angle grinders;
- wall chasers;
- petrol cutters;
- stone-cutting machines;
- slotting and cutting machines.
The principle of operation of diamond discs is to grind the material being processed. During operation, the binder wears off, and the upper blunt crystals fall out, opening access to the next layer of diamonds. If the type of wheel is chosen correctly, the same wear rate of the binder and diamond chips is achieved, that is, diamonds will fall out immediately after they become dull. Therefore, the hardness of the binder directly determines the compatibility of a diamond blade with a particular material. For cutting soft, non-abrasive materials such as porcelain stoneware and marble, discs with a pliable binder or with galvanically fixed diamond grit are best suited. Soft materials that have a strong abrasive effect, for example , asphalt, require the use of discs with a high-strength, abrasion-resistant binder. Metals, concrete, including reinforced, and other hard materials, including those with abrasiveness, require the use of discs with a binder of low and medium strength. In most cases, universal diamond wheels are suitable for such materials.
Main categories of diamond blades
In addition to the properties of the binder, the type of cutting edge largely affects the scope of the tooling. According to this parameter, diamond discs are divided into:
- segment discs— focused on dry cutting, provide maximum productivity. There are diamond discs for concrete;
- solid discs— allow you to achieve the maximum quality of the cut, water cooling is often required for effective work. There are diamond discs for porcelain stoneware and marble;
- turbo discs— have notches on the cutting surface, differ in universality;
- turbo segment discs— combine the features of segment and turbo discs.
When selecting diamond discs, it is also important to consider the compatibility of the tool with the equipment. It is determined mainly by the size of the circle and the operating speed.
Possible errors when using diamond discs
Problems when working with diamond blades appear most often because their parameters are not suitable for the material being processed. Jamming of the disk occurs due to the fact that the diamond grit becomes dull faster than the binder wears out, which causes the cutting surface of the wheel to be polished. In addition, the disc may jam if it is pressed against the material with excessive force. If the disc segments wear out quickly, it means that the binder is too soft for a particular material. Another common mistake in the operation of diamond discs is the discrepancy between the recommended and actual wheel rotation speed, including linear. To prevent this, you should only use discs that are compatible with your hardware.
Processing with diamond discs will be most effective if you adhere to the following rules:
- If it is necessary to cut massive products with diamond discs, it is necessary to first make an incision to a depth equal to approximately 20% of the thickness of the workpiece.
- When working with a hand cutter on stone with a thickness of 20-40 mm, the maximum depth should be set so that the contact of the diamond blade with the material is minimal.
- For processing any materials in small volumes, universal diamond blades can be used.
Diamond discsThis is a high performance and powerful piece of equipment. The main condition for the full disclosure of these qualities is the correct selection of a diamond wheel in accordance with the material being processed.