How do Diamond Tools work?
The manufacturing of precision diamond tools happens for a large variety of applications, materials and industries.
Diamond Tools are typically impregnated with a selected mixture of diamonds and metal alloys achieving the best cutting performance possible. The materials that are normally used are sapphire, glass, granite, tile and more.
The basic idea of using these tools is that the metal bond surrounding the diamonds needs to wear away to keep re-exposing the diamonds in order for them to continue cutting.
Throughout the process, the most crucial part of using the diamond tools is that as machining is done, excessive heat can build and cause damage to both the tools and manufacturing material.
So be mindful of this factor.
How to get the most out of diamond tools?
There are more aspects to look at when getting the most out of diamond tools. Typically the manual book advises on the inspection to be done. But, there are also parts that books don’t explain.
So, to maximise the usage of diamond tools with minimum to no malfunction, there are several basic procedures we follow when using it.
Being a precision tool manufacturer, we are here to help you produce high-end precision tools while making the most out of the diamond tools.
Here’s how we maximise our diamond tools:
- Use suitable RPM of diamond tools
- Use appropriate coolant at point of contact
- Keep diamonds thoroughly exposed at all times
- Use right diamond tool accessories
Use right diamond tools for your application
From the available information that you provide in regards to the products you want us to produce, we can identify the right diamond tools to use when machining.
This knowledge and understanding of materials, as well as the diamond tools functions, are very important. Especially during the machining process. This is to be aware of any unnecessary damage to both the products and the diamond tools.
It is best for you to reach out to dealers and manufacturers like us who can help you define your needs better. We educate our clients on the complexity of the products being machined and the right tools we use throughout the job.
Doing so, we practice transparency while saving costs and time to produce high precision metal products.
Use suitable RPMs of diamond tools
One of the most critical factors in a successful diamond tool usage is the right RPM. If the RPM of the diamond tool equipment runs too fast, it causes friction and generates excessive heat causing damage to the diamond tool. Also, when the diamond tool runs too slow, it drags and creates heat.
Heat is the worst enemy for a diamond tool.
So, the optimum speed of RPM when using the diamond tool plays a huge role in avoiding damage on both the tools and the manufacturing products.
But, as a professional precision tools manufacturer, we use an RPM chart that suggests us suitable diamond tool RPMs for the machining purpose.
The appropriate coolant at point of contact
All diamond tools require some form of coolant flooding the point of contact between the material and tool to keep the diamond tool cool.
Depending on its application, there is a variety of coolants to choose from. Coolants mostly range from plain water, water-soluble coolants to minerals and oils. Typically, water is used for most materials such as sapphire, granite and glass despite no lubricity. Water yet works as a great coolant.
Oil, however, is not a proper coolant, as most diamond tool manufacturers would suggest. The reason being, oil leaves the machine greasy and there are high possibilities to cause contamination. Hence, water is a true organic coolant for most diamond tools.
On the other hand, when machining harder and more dense materials, a better option that we go for is the water-soluble coolant that has better lubricity.
We choose the type of coolant depending on the application and its requirements. Also, deciding which to choose isn’t the biggest determining factor here. Using the coolant only at the point of contact of the material and tool intersect is the need.
Keep diamonds thoroughly exposed at all times
On this part of diamond tools, we speak of dressing them appropriately. Diamond tools must be both trued to and dressed on the machine on which it will be used. Doing so will guarantee two things:
- Diamonds will be thoroughly exposed
- The diamond tool will be ‘true in running (T.I.R)‘ on the machine
Truing a tool is the operation of squaring a tool so it runs within one’s tolerances. This is usually done with a hard stone that knocks diamonds out.
The dressing process of the diamond tool, on the other hand, takes place after truing the tool and is necessary to make the diamonds exposed. The diamonds need to stick up exposed from the bone matrix. Or else, it will be difficult for us to handle the tool, especially the new ones.
To know if the diamond tool is thoroughly dressed, we ensure that there are diamond tails extending from the back of the diamonds. From here, we know that the diamond tool should always run in the direction of the leading edge, away from the tail.
So, we make it a point to dress all the new diamond tools before usage. And, ensure to frequently redress the diamond tools while using it.
The right diamond tool accessories
During the cutting process, it is important to use the right size of flanges or wheel stiffener sets. The most appropriate ones will come with thin diamond blades to firmly hold the tool in place. Doing so will help us prevent the blade from walking.
And so, making the diamond tool to last up to 75% longer time and minimizes material deformation as well as cracks associated with overheating.
Reliable diamond tool operators manufacture high-quality products
We suggest you consult ASIME, the ISO Certified Precision Tools manufacturer, who has been in the industry for more than 20 years. We speak all high-end precision tools manufacturing.
So look no further as we take great care in our manufacturing processes, and are always following DOE and ISO standards. We ensure that our tools and services are nothing short of world-class.