The Structure and Working Principle of Diamond Saw Blade

Structure of diamond saw blade

1. Basics

The base of a diamond saw blade serves as the foundation for the segments. Typically made of high-strength steel or other durable materials, the base is designed to withstand the stresses and forces generated during the cutting process. It provides stability and rigidity, ensuring the saw blade maintains its shape and performance throughout its service life. The base also plays a crucial role in bonding the cutting head to the saw blade, effectively transmitting cutting forces.

2. Diamond segments

The diamond segment is the most critical component of a diamond saw blade, as it performs the actual cutting. It is embedded with diamond particles, the hardest substance known. It is this diamond content that gives the saw blade its exceptional cutting ability. The diamond particles are typically encapsulated in a metal matrix, which provides strength and durability to the cutting edge.

The design of the segments will vary depending on the intended use. For example, the blade configuration for cutting concrete may be different from that for cutting ceramics. The arrangement and size of the diamond segments on the cutting head will also affect the blade’s performance, including cutting speed and efficiency.

How diamond saw blades work?

The working principle of a diamond saw blade is relatively simple, yet highly effective. When the blade is mounted on a saw and rotated at high speed, diamond particles embedded in the cutting head come into contact with the material being cut. The hardness of the diamond enables it to penetrate and fragment the material, resulting in a clean, precise cut.

Key factors in the cutting process

• Segments Wear: As the blade is used, both the metal matrix and the diamond particles wear. Ideally, the metal matrix wears slightly faster than the diamond particles. This wear pattern helps maintain the cutting head’s sharpness, ensuring the blade continues to perform efficiently for a long time.
• Cooling and lubrication: During the cutting process, friction generates heat, which can cause the blade to overheat and damage. To mitigate this, adequate cooling and lubrication must be applied, typically using water or other cutting fluids. This not only helps maintain the blade’s temperature but also flushes away chips and reduces wear.
• Cutting speed and pressure: The efficiency of a diamond saw blade is also affected by the cutting speed and the pressure applied during cutting. Optimal cutting conditions can improve the performance of the saw blade and extend its life.

Diamond Saw Blade Types and Appearance Classification

Type classification

1. Sintered diamond saw blade

Sintered diamond saw blades are made by pressing and sintering diamond particles into a metal matrix. There are two main types of sintered diamond saw blades:

• Cold-pressed and sintered blades: This method mixes diamond particles with metal powder and then presses them at room temperature. The pressing process creates a strong bond, and the blade is then sintered at high temperatures to enhance its strength and durability. Cold-pressed blades are typically used for cutting softer materials.
• Hot-pressed sintered blades: This method applies both heat and pressure during the pressing process. The combination of heat and pressure creates a denser, stronger blade. Hot-pressed sintered blades are ideal for cutting harder materials and are known for their durability and cutting efficiency.

2. Welding diamond saw blades

Welded diamond saw blades are classified according to the welding technology of the diamond segment and the saw blade body. There are two main types:

• High-frequency welded blades: In this process, a high-temperature molten medium is used to weld the diamond tip to the blade base. This method creates a strong bond capable of withstanding the stresses of cutting hard materials. High-frequency welded blades are renowned for their durability and excellent cutting performance.
• Laser-welded blades: Laser welding uses a high-temperature laser beam to melt the edges of the diamond tip and blade base, creating a metallurgical bond. This method allows for precise control of the welding process, resulting in a strong and reliable bond. Laser-welded blades are typically used in high-performance applications.

3. Electroplated diamond saw blade

Electroplated diamond saw blades utilize an electroplating process to attach diamond particles to the blade base. This process electrochemically deposits a layer of metal onto the blade, firmly securing the diamond particles. Electroplated saw blades are often used for precision cutting applications, such as glass and ceramics, due to their fine cutting capabilities.

Appearance classification

1. Continuous Edge Saw Blade

Continuous-edge saw blades feature a smooth, continuous cutting edge, making them ideal for clean, precise cuts. These blades are typically manufactured using sintering technology, with a bronze bond as the base material. Adding water during the cutting process is crucial to ensure efficient cooling and flushing away debris, helping to maintain cut accuracy. Continuous-edge saw blades are commonly used for cutting tile, ceramics, and other similar materials.

2. Segment saw blade

Segmented saw blades feature a unique design with segmented teeth for increased cutting speed and efficiency. The segmented design allows for better cooling and debris removal during the cutting process, making these blades suitable for both dry and wet cutting applications. Segmented saw blades are widely used in construction and masonry applications where fast and efficient cutting is required.

3. Turbine saw blade

Turbine blades combine the advantages of segmented blades with a continuous turbine tooth profile. This innovative design not only increases cutting speed but also extends blade life. Turbine blades are particularly well-suited for cutting tough materials, offering a perfect balance of performance and durability.

Diamond Saw Blade Parameters and Influencing Factors

Key parameters affecting diamond saw blade performance

1. Sawing parameters

Sawing parameters are key factors that directly affect the efficiency and life of diamond circular saw blades. These parameters include:

• Blade linear speed: Blade linear speed is a key factor affecting cutting efficiency and blade wear. It is affected by equipment performance, blade quality, and the characteristics of the material being cut. For example, when cutting granite, the linear speed is typically set between 25 and 35 m/s. Setting the appropriate linear speed for the material will help extend blade life and improve cutting efficiency.
• Depth of cut: Depth of cut is another key parameter that influences diamond wear, effective cutting, and blade stress. When operating at high wire speeds, a smaller depth of cut is typically selected for safety and efficiency. Current technology allows for flexible adjustment of the depth of cut between 1 mm and 10 mm, depending on the material and cutting conditions.
• Feed rate: Feed rate refers to the speed at which material is fed into the blade. It significantly impacts cutting efficiency, blade stress, and heat dissipation in the cutting area. The optimal feed rate should be determined based on the characteristics of the material being cut, as it affects the overall performance of the cutting process.

Other influencing factors

In addition to the main sawing parameters, there are several other factors that affect the performance of diamond saw blades:

1. Blade type and quality

The type and quality of a diamond saw blade are crucial to its cutting performance. Different blade designs, such as continuous edge, segmented, and turbine, are suitable for various applications and materials. High-quality saw blades made from premium materials tend to perform better and last longer.

2. Coolant usage

Using coolant during cutting is crucial for maintaining optimal blade temperature and reducing wear. Coolant helps dissipate heat, preventing the blade from overheating and extending its life. Adequate coolant also helps flush away chips, preventing them from scratching and damaging the workpiece.

3. Material moisture content

The moisture content of the material being cut can also affect cutting performance. Materials with higher moisture content may require different cutting parameters than dry materials. Adjusting sawing parameters based on moisture content can help optimize cutting efficiency and saw blade life.

4. Diamond grit selection

Selecting the right diamond grit size is crucial for achieving the desired cutting result. Common diamond grit sizes range from 30/35 to 60/80, with finer grits providing a smoother surface and coarser grits increasing material removal rates. Choosing the right grit size for the material and desired finish is crucial for effective cutting.

5. Segment density and bond hardness

• Segment density: The density of a diamond segment is usually measured by the weight of diamonds per unit area. It affects the cutting performance and wear resistance of the saw blade. The higher the segment density, the better the cutting efficiency and durability.
• Binder bond hardness: The hardness of the bond that holds the diamond particles in place directly affects the wear resistance of the blade. A harder bond may be better for cutting harder materials, while a softer bond is better for cutting softer materials.

6. Force, temperature, and wear

When cutting stone or other hard materials, diamond circular saw blades are subjected to a variety of forces, including cutting forces and thermal stress. These forces cause wear on the saw blade, affecting its performance and service life. Understanding the effects of these forces and controlling them through appropriate sawing parameters is crucial to maintaining the integrity of the saw blade.