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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