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A Diamond Tool Works Like This

A Diamond Tools is made of two parts: a steel base and diamond impregnated segments. The steel is of high quality and strength. The diamond segments are attached in following manner: continuous, separated, or continuous castellated.

Each type of diamond tool serves a specific purpose. The tools which require more cooling are made with separated diamond segments. The gaps between the slots of separated rim allows the water to flow through the blank during the cutting to prevent the tool from overheating. The segments are slightly wider than the steel base, to prevent the friction which could have occurred with the contact of steel and the substance.

The diamond segments are metal bonded, impregnated with diamonds. The select diamonds are mixed and sintered with selectmetal alloys to achieve the best cutting performance possible on any materials such as granite, marble, sand-stone, lime-stone, slate-stone, etc. The metal bond surrounding the diamonds must wear away constantly to keep re-exposing the diamonds for continuous cutting.

The tool may become overheated if the cooling mechanism is not taken care of. Which may result in metal bond not wearing away, instead it'll glaze over the diamond. Hence coating or covering the diamond.
The metal bond then becomes the cutting agent rather than the holding agent. Generating more heat. At the end of the day,thetool will chip or break the substance. Same heat may harmthe tool itself, by causing heat cracks in the diamond section. This has been a frequent problem with most conventional diamond tools. Much of this has been resolved with the introduction of latest machines and advanced technology adopted by Sharp.

How Optimum Performance Could Be Achieved.

Each diamond tool is designed specifically for each application, and hence may react differently under different conditions. What work for one application, may not work for another. Yet, there is one thing all diamond tools have in common:

They are metal based products being used to cut natural stones. Their use generates friction, which in turn can generate heat. Doing so, may damage your diamond tools.In order to prevent this from occurring, there a number of basic procedures you can follow that will allow each diamond tool to operate successfully no matter what substance you are processing.

Although we realize than in many circumstances, there are a variety of factors that may prevent you from following all the suggested procedures. And not all jobs or operations can be done in a controlled environment such as a shop or lab. Nor all equipment on the market can be adjusted to suitably accommodate a diamond tool needs.

To set optimum performance out of any diamond tool, one has to consider many factors for selecting and using it. If we neglect these important points, even an excellent tool will perform badly. Here we shall discuss these points for educating the end users to get the best return on investment and a trouble free operation.

  • Material being processed
  • Process: Dry or Wet
  • Machine you are using
  • RPM of the Machine
  • Coolants and it's quality
  • Flange Size
Material Being proceed
Process: Dry or Wet
Machine you are using
RPM of the machine
coolant and its quality
Flange Size

Process: Dry or Wet

Often the decision of cutting wet or dry depends on your preference and job requirements.

Dry cutting eliminates messy wet slurry and the need to equip saws with water tanks and hoses. For indoor jobs where you need to keep the work area dry, a dry-cutting blade and compatible saw may be your only option. If you're sawing decorative pattern lines in concrete, dry-cutting blades are often the best choice for making crisp, clean cuts.Dry-cutting blades have segment welds that resist heat and don't require water for cooling. They are usually intended for intermittent cutting and for use on handheld, low-horsepower saws

Using a blade wet, on the other hand, reduces dust but makes it necessary to contain or clean up the slurry.Wet-cutting blades are typically used with walk-behind saws for cutting joints in cured concrete flatwork because water cooling permits deeper cuts.

Although it's possible to use most dry-cutting blades with water, but never use a wet-cutting blade dry.

Coolant and its Quality

All diamond tools require some form of coolant flooded at the point of contact to keep the diamond tool cool and lower the friction.Depending on your application, there is a large variety of coolants you can select.Ranging from plain water, to water soluble coolants, to minerals and oils. Your specific application will be a determining factor in selecting a coolant.

Not matter what coolant youdecide to use, make sure it is used at the point of contact where material and tool intersect.When a tool is running at the right RPM, momentum will throw the coolant away from the point of contact. This will generate heat and the tool will glaze over with the bond no longer allowing diamonds to function.

Nowadays, water ismostly used as a coolant, make sure that the water is clean and free of slurry and other impurities. Water can be used as a coolant for most materials, such as granite, marble, sand-stone, lime-stone and slate-stone. Although water is a not a lubricating agent but it is a true organic coolant, which does not leave the work surface oily, greasy, or contaminated. Water does turn to steam at temperatures exceeding 100 degrees Celsius. So, adding a non-sudsing detergent will help water provide more lubricity and serve longer as a coolant. Occasionally, it may be necessary to move from water to water soluble coolants. Such as when machining harder and denser materials.

We recommend that you use water or water soluble coolants for most application.

Flange Size

When cutting, use the right size flanges or wheel stiffener sets with all thin diamond blades to firmly hold it in place. This will help prevent the blade from walking. Use Drill Head Assemblies with core drills to provide coolant (water) through the center of the drill and on to drilling zone.

RPM of the Machine

One of the most critical factors in successful diamond tool usage is the right RPM.s. If thediamond tool rotates too slowly, it drags and creates heat. If it spins to fast, it causes friction and again generates heat. Heat is the worst enemy for a diamond tool. Selecting the right RPM becomes a critical factor of success. Unfortunately, this can also be the most difficult aspect of cutting or drilling to be decided, unless you have a machine with variable speed capability.Most machines will only run at 1,725 to 3,450 RPM.If you use diamond tools on a regular basis, you may want to consider varying yourmachinery to accommodate variable speed capability. Frequent dressing, using right coolants, and using right flange sizes orwheel stiffeners can help. But will notcompletely substitute for correcting RPM

Other Tips

Keep diamonds thoroughly exposed at all times

Dress your new diamond tools before usageit to make sure the diamonds are exposed. Make sure to frequently redress your tool while using it.It is recommended that the tool is passed through five to ten times to expose the diamonds for optimum cutting performance.A diamond tool that is thoroughly dressed will have diamond tails extending from the back of the diamond.This means it should always run in the direction the leading edge of the diamond, away from the tail. So the sharper, leading edge of the diamond can achieve desired cutting action.

Use the right diamond tool accessories

Even though your cut may not be very deep, your machine may only accommodate a specific blade diameter. When your blade cuts into your material, it may not have the rigidity to maintain the tolerance. The blade may begin to walk. Although we use special alloy steel cores to minimize this problem. We suggest you insure maximum performance from your new diamond blade by using wheel stiffener.

Never force your diamond tool

After using your diamond tool for a while, it may seem to cut more slowly or begin to chip your material. This is because the diamonds are no longer exposed. Never force your diamond tool. If you feel

  • resistance in cutting
  • diamond tool is not cutting as easily
  • diamond tool is slowing down
It is important to stop and dress the wheel again.

The Thumb Nail Test

We recommend you give your new diamond tool the 'Thumb Nail Test'. After thoroughly dressing the tool, you should be able to snag your thumb nail on the diamonds. This'll let you know whether they are exposed in order to cut properly.

Keep your tool trued

Remember that every machine runs differently. And even if the diamond tool is trued at the factory, it can still run-out of tolerance when you place it on your machine. Blades must be trued. Truing a tool is the operation of squaring a tool so it runs within your tolerances.