Diamond Core Bits and Blades: What makes them cut faster and last longer?

What makes Diamond Core Bits and Blades cut faster and last longer?

To select blades or bits for cutting concrete, a contractor doesn’t need to know how they are made, but should know how they will be used, meaning the type of concrete to be cut and the machine being used to cut it. A manufacturer of concrete cutting equipment can then recommend a blade or bit that will match the concrete and the machine.

TYPES OF BLADES

Diamond bits and blades are made by brazing diamond segments to the end of a steel tube or the perimeter of a steel disc. Each diamond segment consists of several diamond particles held together by a metal bond. To make segments that will cut different types of concrete, manufacturers vary the composition of this metal bond and the type, size and concentration of diamonds. Most contractors prefer to use wet-cutting diamond blades whenever possible, because the water used to cool the blade also eliminates dust. The slurry that’s produced can easily be vacuumed up.

FACTORS THAT ALTER CUTTING PERFORMANCE

Type of Aggregate–Hard aggregates shorten blade life and slow the cutting rate, so cutting concrete with a hard aggregate such as quartz will cost much more than cutting concrete with a soft aggregate such as limestone. Size of aggregate is also important.

Reinforcing steel–It costs more to cut concrete that contains reinforcing steel because blade life or bit life is shorter and cutting rates are slower.

Operating speed–To keep blades from distorting at high speeds, they are manufactured in the form of a dish that will straighten when the blade is rotated at optimum speed. If the design speed is not achieved, the blade will tend to wander as cutting commences.

Depth of cut–Making deep cuts will generally cost less than making two or three shallow cuts. By Mark Wallace

3 Tips for Choosing the Right Diamond Saw Blade

Choosing the right diamond blade can mean the difference between an efficient, cost-effective, profitable job or one with additional costs and downtime. Knowing how to select the right blade for the right machine that is designed to cut the right material can save time, money and increase profits. Owners should ask themselves these three basic questions when choosing a blade for a project and use this knowledge to correctly bid on projects as well as minimize the chances of troubleshooting blade issues.

1. Which materials are you cutting?
Correctly identifying the material to be cut directly affects the cutting speed and the life of the blade. Most blades are designed to cut a range of materials, which is limited by the hardness of the bond and the diamond quality used. However, for maximum performance, the blade should be matched as closely as possible to the material it will cut.

When cutting concrete, asphalt or green concrete, it is important to know what makes up the material. Knowing the type of aggregate within the slab is your best bet at finding a blade optimally suited to cut it. You can determine what is in the slab by observing and looking to see what aggregate is used, or by using a Mohs test. A Mohs test helps identify the hardness of the aggregate, which can help determine what type of aggregate you are up against. Most diamond blade manufacturers will specify which of their blades either cuts a particular type of aggregate (flint, river rock, limestone or abrasive sand, for example) or will list aggregate categories (hard, medium or soft). These aggregate and material charts will help narrow your blade selection to only the blades that will cut that particular type of aggregate.

2. What type of equipment are you using?
Knowing if you will be using a 5-hp power cutter or a 70-hp flat saw will impact blade choice dramatically. The size of the blade acceptable to use on the saw, the ability to use a wet or dry blade and the rpms needed to spin the blade all depend on the equipment.

  • Blade size—Blades are engineered to be used on specific equipment. It is critical to select a blade that can be run on the equipment you plan on using.
  • Wet or dry blades—Most equipment will have the ability to use water, but there may be a time when water can’t be used or isn’t available.
  • RPMs—If a blade is run too fast or too slow, the blade will not work effectively and a loss of tension or excessive wear on the blade could result. Blades should list a maximum safe speed in revolutions per minute at which a blade can be used. Before using any blade, make sure the blade shaft (arbor) speed or the tool is within the “maximum safe” limit of that blade.

3. How deep are you cutting? 
Knowing how deep you need to cut on a particular job will help you select the right blade diameter. Maximum cutting depths listed on blade packaging may vary from what it actually cuts in the field. Actual cutting depth will vary with the exact blade diameter or saw type or the exact diameter of the blade collars (flanges). Cutting depth will also be reduced if saw components (motor housing and blade guard) extend below the blade collars.

 

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