Diamond blades troubleshooting guide

FACE RUN-OUT

Causes:

• Deformation of the core;

• face run-out of the mounting and clamping flanges or power drive shaft;

• insufficient rigidity of the core;

• lack of parallelism relative to the movement of work blank and tool; loose fixation of the tool.

RADIAL RUN-OUT

Causes:

• Radial run-out of mounting shaft or adapter ring;

• defective inner hole of the core (power drive shaft);

• uneven wear of the segments;

• uneven feed of the blade/material during cutting process;

• wear-off of mounting shaft’s diameter

DEFORMATION OF THE CORE

Causes:

• Impact force on the core; jamming during cutting;

• low cutting ability of the segments;

• loss of core’s rigidity due to incorrect straightening or overheating;

• lack of overhang of diamond segments over the core;

• over the limit depth of cutting;

• overload during cutting

UNEVEN WEAR OF SEGMENTS

Causes:

• Radial run-out of the cutting tool;

• vibration of spindle and/or work blank

CRACKS ON THE CORE

Causes:

• Loss of rigidity of the core due to overload (over the limit cutting depth or feed speed);

• radial run-out of the tool;

• jamming during cutting;

• poor quality of the steel in the core

LACK OF CUTTING ABILITY

Causes:

• Incorrect choice of tool relative to processed material;

• incorrect cutting modes (revolution speed of the blade too high;

• over the limit cutting depth;

• low feed speed); excess water

CRACKS ON THE SEGMENTS

Causes:

• Low cutting ability of the segments;

• overload during cutting;

• radial run-out of the blade

BREAKAWAY OF SEGMENTS

Causes:

• Jamming during cutting;

• poor quality of segment attachment to the core (brazing, welding);

• overheating in the cut zone due to insufficient water feed;

• deformation of the core

CORE WEAR-OFF IN THE SEGMENT ATTACHMENT ZONE

Causes:

• Incorrect choice of tool relative to processed material;

• rubbing over of the core during cutting due to lack of overhang of the segments over it;

• ineffective removal of highly abrasive particles of sludge residue from the cut zone;

• face run-out

EXCESSIVE NOISE, VIBRATION

Causes:

• Polishing of diamond layer of segments due to incorrect cutting modes;

• wear-off of the spindle bearings;

• loose fixation of the blade in the machine;

• work blank not fixated;

• loss of core’s rigidity;

• breakaway of segments.

JAMMING DURING CUTTING

Causes:

• Work blank not fixated;

• adding up the cutting parts of the work blank;

• lack of parallelism relative to movement of work blank and tool;

• lack of perpendicularity of mounting flange’s end relative to surface of work table;

• lack of overhang of segments over the core; deformation of the core

HIGH WEAR OF SEGMENTS

Causes:

• Incorrect choice of tool relative to processed material;

• not optimal cutting modes (lowered revolution speed of the blade;

• lowered cutting depth;

• higher feed speed);

• radial and/or face run-out.

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