This article explores the use of diamond blades, from cutting hard building materials to semiconductor manufacturing.
For more information, please visit what is a diamond blade used for.
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Diamond saw blades are created by bonding diamond grit to the blade's steel body, resulting in a stronger blade capable of cutting even the hardest materials.
Diamond Blades and Building Materials
Diamond is one of the hardest naturally occurring materials known to man. In a diamond blade, synthetic diamond materials are mixed with other materials such as iron or steel to form the blade with diamond segments along the cutting edge.
Diamond blades are generally used for cutting hard materials. The produced blade is suitable for cutting a wide variety of materials, including concrete, granite, ceramic tile, asphalt, bricks, and other hard stones, as well as nearly any other type of building material.
Advantages of Using Diamond Blades for Building Materials
When used on suitable materials, diamond blades are extremely durable and have an outstanding lifespan. Due to the nature of these blades and the variety of options available, users can expect blades to last a longer period when a suitable blade is chosen for a specific material.
Diamond blades cut quickly, which expedites the cutting process and reduces noise-related concerns in the workplace. With a high-quality and material-appropriate diamond blade, the amount of noise generated is significantly reduced; less resistance equals less noise.
These blades generate less heat during operation due to less friction. With the proper blade and the correct usage of a cooling system, little to no heat is generated, resulting in a comfortable and efficient cutting process.
Limitations of Diamond Blades for Building Materials
The disadvantages of diamond include its low thermal stability, chemical reactivity with iron group elements, and carbonization at 700 to 800 degrees celsius, which normally do not apply to steel production.
The same holds true when cutting nickel-based alloys. Researchers do not usually advocate using diamond cutting tools made of high melting temperature metals or alloys. Additionally, grinding diamond tools is time-consuming and costly.
Diamond Blades in Semiconductor Manufacturing
The use of diamond blades in semiconductor manufacturing has improved wafering processes and resulted in significant cost savings in device fabrication. Additional gains in wafer productivity and quality can be achieved by adopting a systems-based approach to the slicing procedure.
Advancements, such as stainless-steel diamond wheel cores and increased cutting speeds, have resulted in considerable cost savings for both materials processors and device makers.
Today, automated factories with high throughput for workpieces up to 400 mm in blade diameter are available. Slicing involves numerous factors including wheel attachments, crystal mounting for slicing, coolant selection, handling, and worker skill and competency. Controlling all of these factors precisely can lead to further improvements and cost savings throughout the wafering procedure.
Problems of Diamond Blades in Semiconductor Manufacturing
Slicing concerns are becoming more challenging as bigger and longer crystals are produced. While bigger, longer crystals increase processor efficiency, they also introduce complications because current slicing machinery is not built to handle such large workpieces.
Larger dimensions also result in more waste when rejections occur. With new semiconductor materials costing up to 20 to 30 times the price of silicon and germanium, significant kerf losses and high reject rates are too costly. The geometry and surface polish of a wafer dictate its quality.
Solutions to Improve Diamond Blades in Semiconductor Manufacturing
After mounting the blade on the machine, it is tested for concentricity. Friction and heat may release strains in the core material during operation, allowing tension to relax. Therefore, machine tensioning is a common procedure.
The diamond wheel head should be dynamically balanced, with clean, parallel, and smooth clamping surfaces. The diamond materials must be carefully chosen for their particle size, strength, and shape. Lastly, the diamond blade must be handled with care. It must be installed, tensioned, polished, and operated correctly.
All of these elements contribute to the efficient and precise slicing of semiconductor wafers to precise tolerances with minimal kerf loss and product damage.
References and Further Reading
Dobrescu, T., et al. (2013). Improving the slicing process characteristic parameters. Proceedings in Manufacturing Systems. Read More
Li, K., et al. (2019). Analysis of the Dynamic Diameter of Superthin Diamond Blades in the High-Speed and Precision Dicing Process. International Journal of Precision Engineering and Manufacturing volume 20 pages1071–1081. Read More
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Can Diamond Blades Cut Metal? Everything You Need to Know
Why Use Diamond Blades?
In today's modern age, structures and buildings often incorporate concrete and other hard metals, which aren't easy to cut with regular saws.
Hard materials require even stronger materials to cut through, and that's where diamond comes in.
Diamond is the hardest naturally occurring substance known to man, making it ideal for cutting hard materials like tile, steel, and concrete.
On the Mohs Hardness scale, diamond is rated 10, the highest achievable rating. Due to their rarity, diamonds are pricey, so diamond blades typically use synthetic (man-made) diamond.
Without synthetic diamonds, cutting hard materials would be virtually impossible.
These blades also offer several advantages over other metal and abrasive blades:
Safer to Use
Last Much Longer
Cut Much Faster
Will Diamond Blades Cut Metal?
Yes, certain diamond blades can cut through metal, but this depends entirely on the blade's application.
Most diamond blades are used to cut through concrete, brick, tile, and asphalt. However, different blades have different applications.
For example, "Because asphalt is softer than surfaces like concrete or granite, soft bonded blades won't be effective and typically don’t result in clean cuts. Instead, the best tool for asphalt cutting is a diamond blade with a hard bond."
Some blades are universal and can be used to cut almost all materials. Before buying any blade, do your research to understand its specific application. Check the product packaging and seek advice if unsure.
Can Diamond Blades Cut Steel?
Steel is one of the strongest metals on the planet. When it comes to diamond blades, there are a few specific types that can cut through steel.
For example, the Husqvarna High Pro 3 and 5 series are suitable for cutting through steel bars, but generally, abrasive saws are better for cutting steel, not diamond blades.
Abrasive saws are made of "aluminum oxide grain that is reinforced with two sheets of fiberglass or another insulating material," which is better for grinding through steel.
For more cutting asphalt with angle grinder information, please contact us. We will provide professional answers.
How Do Diamond Blades Cut?
Believe it or not, diamond blades don't actually cut. Instead, they use friction to grind away at the material. "Harder materials are best cut when the bond of the diamond blade is softer. As the diamond particles are dulled and broken, the bond releases so that more of the synthetic diamond can be exposed, grinding away at the material."
"The reverse is true for cutting softer materials. The bond is stronger to ensure that the diamond is exposed long enough to be fully utilized." Essentially, the blades scratch away at the particles of each material.
What Size Diamond Blade Should I Choose?
The size of the blade impacts what you're cutting and the project you're working on. For example, you won't use a 30" diamond blade with a massive cut-off saw to cut kitchen tile. Instead, you'd use a smaller electric saw with a more applicable 4" blade.
The size you choose will depend on what fits your saw. Check the saw's manufacturer manual or product packaging to find out the blade diameter it requires.
How Long Do Diamond Blades Last?
The material you're cutting and how you use the blade will largely determine its lifespan. Generally, diamond blades last about 100 times longer than other abrasive-type blades.
The quality of the blade also plays a role:
Remember, buying cheap is often more expensive in the long run.
Diamond Blade and Saw Safety Tips
Any blade and saw are dangerous, spinning at a few thousand Revolutions Per Minute (RPM). Combine that with a blade made of the hardest material on earth, and you have a serious cutting machine. Here are some tips to keep you safe:
Wear the Proper Safety Gear
Cutting with a circular or road saw will cause debris to go flying everywhere. Wear gear that protects you, especially your face:
Follow Manufacturer Directions
Just like a car needs specific fuel, saws and blades have their own instructions. Always check the manufacturer's manual and product packaging for proper safety and handling.
Don't Force It
Forcing the saw is a bad idea. Avoid pushing it too hard. Even diamond blades have their limits and can crack, chip, or break.
Cut Straight
Do not cut at such an angle that the sides of the saw do any cutting. The blades are only designed to cut at the edges, not the flat sides.
Cool Down
Saws get very hot, very fast. There’s a lot of power and friction involved in grinding away materials like concrete, brick, and asphalt. If your saw doesn’t use water for cooling, take breaks to let it cool down. The harder the material, the more cooldown time you need.
Cut Only What’s Recommended
Many blades are designed to cut specific materials. Avoid cutting materials you're not supposed to. Follow the manufacturer's recommendations to prevent the diamond blade from wearing down or ripping through inappropriate materials.
Routine Maintenance Checks
Before operating any saw with a diamond blade, ensure nothing is damaged. Check both sides and the edges of the blade to make sure it's ready to use.
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