Life of the diamond tool is primarily controlled by amount of diamond crystal in the bon matrix. This amount is called “diamond concentration” higher the diamond concentration a diamond tool has, the longer its life time. The trade off is slower cutting speeds.
AMOND CONCENTRATION - The proportion, and distribution of diamond abrasive particles, also known as concentration. has an effect on overall cutting performance and price of precision diamond blades. Diamond concentration, commonly referred to as CON, is a measure of the amount of diamond contained in a diamond section of drill based upon volume. Diamond concentration is usually defined as: Concentration 100 = 4.4 ct per cm layer volume (mesh size + bond). Based on this definition a concentration of 100 means that the diamond proportion is 25% by volume of diamond layer, assuming at diamond density is 3.52 g/cm3 and 1 ct = 0.2g. Nominal diamond concentration in precision diamond blades range from 0.5 ct/cm3 to 6 ct/cm3. This means diamond concentrations are available from 8 to 135). Selecting the Right Diamond Concentration can be critical in optimizing your Precision Diamond Sawing Operation. Selecting Optimum Diamond Concentration for your application will depend on a large number of factors, such as:
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Material Being Cut
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Bond Type and Hardness
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Diamond Mesh Size
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Cutting Speeds
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Coolants being used
Diamond Concentration will play a major role in determining the life and cutting speed of your High Precision Diamond Blade. Higher diamond concentration is recommended and usually used for cutting softer and more abrasive types of materials. However, the trade off is significantly slower cutting speed. Low diamond concentration is recommended and widely used for cutting ultra hard and brittle materials. Diamond Concentration is usually determined by the the slowest cutting speed that is acceptable for a specific application. Optimum performance can be achieved when the diamond tool manufacturer utilizes their experience and analytical capabilities to balance diamond concentration and other factors to achieve optimum performance for the tool operator. UKAM Industrial Superhard Tools has the experience & applications laboratory to help you select all the right diamond blade variables for your unique application
Example of diamond concentration uses on various applications:
25 – Satisfactory of soft nonabrasive materials. May not be satisfactory where production requirements are high
50 – recommended for most materials and satisfactory in production use
100 – for extremely hard dense materials and where smoothness of cut and close tolerances must be met.
Diamond Concentration & Cutting Performance
Today, most Production and R & D facilities use low concentration diamond blades for cutting ceramics, glasses, silicon, carbides, sapphire, and other related semiconductor and optical materials. And use high concentration diamond blades on metals such as stainless steel, aluminum, titanium, pc boards. A new technological breakthrough called SMART CUT™ technology, is making fundamental changes in these beliefs and setting new benchmarks on how diamond blade performance is measured. SMART CUT technology allows the orientation of diamonds inside the metal matrix, so that every diamond is better able to participate in cutting action, By orienting diamonds, SMART CUT™ technology makes diamond concentration only a minor factor in the overall precision diamond equation. Studies and extensive testing shows that diamond concentration in diamond blades manufactured utilizing SMART CUT™ technology plays a no major role in determining overall diamond blade performance.
Large number of diamonds in a high concentration diamond blade come in contact with material, creating friction, hence considerably slowing down material removal rate. It takes considerable dressing in order to rexpose the next diamond layer. SMART CUT™ technology resolves this problem by making sure that every diamond is in the right place and at the right time, working where you need it most. You get maximum use of diamond and bond. Before this technology was developed, orienting diamonds inside the blade bond matrix was considered impossible. This was one of the main problems faced by diamond tool manufacturers worldwide.
Over the decades there have been numerous attempts to solve the diamond and CBN distribution problem. Unfortunately, none of the attempts have been proven effective. Even today 99.8% diamond blade manufacturers still have no way or technology to evenly control and distribute Diamond or CBN particles inside bond matrix, nor properly position them to maximize their machining efficiency.
Diamond Concentration & CBN (cubic boron nitride) blades
For CBN (cubic boron nitride) concentration is defined by volume. For example V120 = 12% by volume, V180 = 18% by volume.
ARE YOU USING RIGHT TOOLS
FOR YOUR APPLICATION?
HAVING ISSUES WITH
YOUR CURRENT TOOLS?
What you should know
your next diamond tool?
How to Selecting Right Diamond Tools for your application
How to properly use Diamond Tools
Why use diamond
How Diamond Tools Work
What is SMART CUT Technology
Diamond Wire Advantages & Application
What is Diamond Mesh Size and how to select best one for your application
What is Diamond Concentration and which to use for your application
Diamond crystal quality – you get way you pay for
Diamond impact strength
Diamond Tool Bond Hardness & wear resistance
Material Holding Methods
Material Guide
Silicon Fabrication Guide
Diamond Tool Coolants Why, How, When & Where to Use
Diamond vs CBN (cubic boron nitride) Tools
Dressing Diamond Tools Why, How, When & Where
Get to Know the Diamond Tool Bond Types and Which to use for your application
RPM’s & Feed Rates
What is Surface Finish
What are Tolerances, Accuracy, and repeatability
Diamond Tools compared with Abrasive Tools
Diamond vs. Laser and Water Jet
Diamond Wire vs band saw blades and circular blades
What is Chemical Vapor Deposition and its application
What is Polycrystalline Diamond and its application
What are diamond dressers and their application
How Diamond Tools are Manufactured
