Diamond saw blades are essential tools for a wide range of industries and are renowned for their precision and efficiency in cutting hard materials. The construction of diamond saw blades mainly consists of two components: the saw core and the cutter head. Among them, the diamond cutter heads are crucial to the cutting performance because they directly affect the efficiency of the saw blade. The production of diamond cutter heads is a meticulous process involving multiple steps, each of which requires precise operation and strict quality control. This article details the production process of diamond saw blades in a factory.

1. Raw Material Preparation

A. Diamond particles

The first step in diamond segment production is to prepare diamond particles, which are the cutting agents in the blade.

Choose

The choice of diamond grain is critical and depends primarily on two factors: the hardness of the material to be cut and the required cutting efficiency. Both natural and synthetic diamonds are commonly used in this process. Synthetic diamonds are preferred due to their uniformity and cost-effectiveness.

Filter

Once the appropriate diamond grain has been selected, it needs to be screened. This requires sorting the grains through sieving to ensure a uniform grain size. Consistent grain size is critical to achieving reliable cutting performance as it affects the cutting speed and life of the blade.

B. Adhesive Materials

In addition to the diamond particles, a bonding material is required to bind the diamond segments together and attach them to the core of the blade.

Metal powder

Commonly used metal powders include iron, copper, cobalt and nickel. Choosing the right metal combination depends on the specific application requirements of the diamond saw blade. For example, when cutting materials with higher toughness, a harder metal can be selected, while when cutting materials with lower requirements, a softer metal can be used.

Additives

To increase the strength and wear resistance of the bond, various additives such as carbides and oxides are added to the mix. These materials improve the overall performance of diamond segments, ensuring they can withstand the rigors of cutting operations.

2. Mixing and Granulation

A. Mixed

The first step in producing diamond segments is to mix the diamond particles with the bonding material. This process is critical to ensure that the diamond particles are evenly distributed in the bonding matrix.

Equipment

To achieve a homogeneous mixture, manufacturers typically use ball mills or specialized blenders. These machines are designed to mix diamond particles and metal powders in specific proportions, ensuring the right amount of each material.

Unity

It is critical to ensure a homogeneous mixture. Each diamond particle must be fully coated with the metal powder to ensure optimal bonding in subsequent steps. An uneven mixture will result in inconsistent cutting performance and shortened blade life.

B. Granulation

Once mixing is complete, the next step is granulation. This process converts the mixed powder into granules, making them easier to handle and press.

Purpose

Granulating the mixed powder helps to form granules that are easy to press. The granules must have good flow and compression properties to ensure consistent density and strength of the final pipe section.

Method

Granulation can be performed in a variety of ways, including:

Spray granulation: This method involves spraying a liquid binder onto the powder mixture to agglomerate it into granules.

Mechanical granulation: This method uses mechanical forces to compact the powder mixture into granules. This can be achieved by various mechanical devices that apply pressure and shear forces.

3. Pressing and Molding

After granulation, the next critical step is pressing and forming the diamond tool segment. This process involves shaping the granulated powder into the desired tool segment shape.

A. Mold Preparation

Prior to pressing, the die must be prepared to ensure the segments are formed correctly.

Design

The molds are designed according to the specific shape and size requirements of the diamond segment. Typically, these molds are made of high-strength steel to withstand the pressure generated during the pressing process.

Cleaning

It is critical to ensure that the mold surface is clean and free of impurities. Any contaminants will affect the quality of the segment and cause defects or flaws in the final product.

B. Powder pressing

The pressing process can be carried out using two main methods: cold pressing and hot pressing.

Cold pressed

The cold pressing process is to place granular powder into a prepared mold and apply high pressure with a cold press. This method can compact the powder into a solid without heating. The cold pressing process can effectively produce high-density and high-strength pipe segments.

Hot pressing

Some diamond segments require hot pressing, which involves pressing powders at high temperatures. This process not only compacts the powder, but also strengthens the bond between the diamond particles and the metal matrix. The high temperature helps melt some of the metal powder, creating a stronger bond, which increases the overall density and strength of the segment.

4. Sintering Process

The sintering process is a critical step in the production of diamond segments as it solidifies the bond between the diamond particles and the metal matrix, resulting in a durable and effective cutting tool.

A. Sintering temperature control

Equipment

To achieve the best sintering results, manufacturers use specialized equipment, such as vacuum sintering furnaces or hydrogen-protected sintering furnaces. These furnaces provide the controlled environment that is critical to the sintering process.

Temperature curve

Developing an accurate temperature profile is critical to successful sintering. This profile is based on the material properties of the diamond particles and the bonding material. The sintering process involves gradually heating the mixture to a preset temperature, ensuring that the diamond and bonding material are completely sintered. This precise temperature control helps prevent damage to the diamond while promoting effective bonding.

B. Sintering Procedure

Degassing

During the sintering process, any gases that may be trapped in the material must be removed. This step, called degassing, is critical to preventing porosity from forming in the final tool tip. Porosity weakens the structure of the tool tip and negatively affects its cutting performance.

Soak

Once the desired temperature is reached, the segment is held at that temperature for a specified time. This soaking time allows the diamond particles to fully bond with the metal matrix, forming a dense and strong segment structure. The soaking time is carefully calculated to ensure that the bonding process is complete and does not compromise the integrity of the diamond.

5. Post-Processing

After the sintering process is completed, the diamond segments undergo several post-processing steps to ensure they meet performance and quality requirements.

A. Cutting and trimming

Cutting

The first step in post-processing is to cut the sintered segments into the desired size and shape. This is usually done using precision cutting tools that can withstand the hardness of the segments without causing damage.

Prune

After the cut is complete, the cutter head needs to be trimmed to achieve a smooth surface and precise dimensions. This step usually includes grinding and polishing to remove any rough edges and ensure a high-quality surface finish. A well-trimmed cutter head not only improves its aesthetics, but also its performance during the cutting process.

B. Inspection and classification

Quality control is a critical aspect of the manufacturing process and thorough inspection and sorting of diamond segments is essential to ensure they meet industry standards.

Visual Inspection

Each batch of segments is visually inspected for defects such as cracks, nicks or porosity. Early detection of these defects helps prevent substandard products from entering the market.

Size check

Manufacturers use precision measuring tools to perform dimensional checks to ensure that the segments meet the specified size and shape requirements. This step is critical to ensure the compatibility and overall performance of the segments with the blade core.

Hardness test

Finally, a hardness test is performed to verify that the cutter head meets the required hardness standards. This test ensures that the cutter head will perform efficiently during the cutting process and maintain its integrity over time.

6. Assembly and Packaging

Assembly

Assembly of diamond blades is a critical stage in the manufacturing process where the core and diamond segments come together to form a functional cutting tool.

Welding

The first step in the assembly process is to weld the diamond segments to the saw blade core. This is usually done using advanced methods such as laser welding or high-frequency welding. Laser welding is favored for its precision and ability to form a strong bond without affecting the integrity of the diamond segment. High-frequency welding, on the other hand, uses electromagnetic energy to heat the material, ensuring a strong connection. The choice of welding method depends on the specific requirements of the saw blade, including its intended use and the material being cut.

Test

After welding the diamond segments to the core, the assembled blades undergo rigorous testing. Inspectors check that the segments are securely connected and show no signs of looseness. This step is critical because any weak link in the connection could cause the blade to break during operation, posing a safety hazard and affecting cutting efficiency.

7. Painting, Laser Marking and Packaging

After the assembly and testing phase, the blades enter the final finishing phase.

Painting

The next step is to paint the core of the blade. Manufacturers will often use specific colors to indicate the type of blade or its intended use. The paint is then allowed to dry thoroughly to ensure a durable coating that can withstand rigorous use.

Laser marking

Once the paint has dried, the blades are laser marked. This process involves printing important information directly onto the blade core, including product model, specifications and safety warnings. Laser marking is preferred for its accuracy and durability, ensuring that the information remains legible throughout the life of the blade.

Protective packaging

To prevent the blades from getting damaged during shipping, they are carefully packaged in protective material. This packaging is designed to cushion the blades and protect them from shock, moisture, and other environmental factors that could affect their quality.

Label

Finally, each package is labeled with important information such as the product model, specifications, and production date. These labels are easy for customers to identify and use, ensuring that they receive the product that meets their needs.

8. Quality Control and Certification

Quality control

Quality control is the cornerstone of the diamond blade manufacturing process, ensuring that each blade meets stringent performance and safety standards.

Process control

The manufacturer maintains strict quality control at every stage of production to ensure batch-to-batch consistency and stability. This includes monitoring the welding process, inspecting the diamond tips, and ensuring the painting and marking processes are flawless.

Final check

Before the product leaves the factory, we will conduct a comprehensive final inspection. The inspection covers the appearance, size, hardness, welding firmness and other aspects of the blade. Any blade that does not meet the established standards will be reworked or discarded to ensure that only the highest quality products can enter the market.

ISO certification

To further enhance their credibility and commitment to quality, many manufacturers seek ISO certification. This certification demonstrates that the production process meets international quality management system standards. It assures customers that the blades they purchase have been carefully manufactured with extreme precision to meet or exceed industry expectations.

In Conclusion

The manufacturing process of diamond saw blades, especially the production of diamond segments, is a complex and precise operation involving careful selection of raw materials. By understanding the manufacturing steps of these important cutting tools, manufacturers can ensure that their diamond saw blades perform optimally and last for a wide range of applications. Whether used in construction, stone cutting or industrial applications, the quality of diamond saw blades directly affects efficiency and profitability, so the manufacturing process is a key factor in its overall success.