This article deals with the
challenges of cutting following glass material families:
basic recommendations are given
for cutting each glass type and example case studies illustrate some
common glass cutting challenges for various glass types.
Diamond projecting diamond bond chip away the glass by a sort of cracking process. Small chips are produced which combine with the coolant to form glass slurry. The slurry grinds and abrades away the bond between the diamonds, so that in ideal conditions the diamond grains and bond war away at same speed. Hence altering diamond mesh size does not merely alter the surface finish quality, but influences the way the tool operates soon.
On other hand a tool rotating slowly at a lower cutting speed softer effect occurs
SAWING HOLLOW GLASS
In sawing hollow glass cracking off presents enormous difficulties since variations in glass thickness cannot be prevented in mechanically blown glassware. Which consequently contains internal stress. This problem can be solved, the glass workpiece is placed in a wood or plaster form or between the more modern adjustable, pliable, rubber coated metal strips. With either method the glass is firmly held on the table as the table is pushed towards the blade.
Material: Textured glass (soda glass)
Blade used: continuous rim diamond blade 8 to 16 diameter. 16 concentration, bronze bond. Blade use din this example 16 x 0.4 to .072
Cutting rate: about 6.2 in2 / min
Life: 20,000 to 40,000 cuts = 210 to 320 ft2 area of cut = 23,000 ft linear
Blade cost: $0.8 to $0.16 cents / glass
Daily material cutting amount: 80 to 1,500 cuts per spindle per shift
Saving: finish machining, essential after cracking off, is no longer needed with diamond sawing.
Water heaters, to be seen in many kitchens
For cutting pyrex rods of all diameters. Cracking off is virtually impossible, so that diamond saws are used here too.
diamond cut off blades are used mostly for hollow glass and rod
applications. Produced using
phenolic resin as the binder, diamond abrasive as cutting media,
ceramic & other advanced components as filler. Resin
Bond is the softest of all the bonds, frequently used in
applications that require a smooth surface specially glass and
quartz tubing. Resin bond diamond cut off blades allow the bond
matrix to wear faster, and allow for diamond particles/crystals to
break out of their matrix faster, so that new sharp diamond
particles become exposed. This self sharpening characteristic of
resin bond diamond cut off blades, based on faster bond wear out is
what make this blade an excellent choice. Resin
bond diamond diamond cut off blades offer superior cut quality than
any type diamond blade available. Recommended for
applications where cut quality and surface finish is very important.
Compared to their sintered (metal bond) wafering blade counterparts.
Resin Bond Diamond cut off blades offer far superior cut quality
than the finest size metal bond (sintered) bade.
Recommended for cutting hard, materials where low heat
generation or improved surface finish is desired. Most commonly used
at higher speeds. UKAM Industrial
Resin Bond Diamond & CBN Wafering Blades are manufactured with
advanced molding process. Available in a large variety of
geometries, diamond sizes, diamond concentrations, and bond
diamond blades for cutting hollow glass >>>
SAWING THICK GLASS
For this application segmented diamond blades are more commonly used than continuous rim blades. The segmented design has advantages in deep cuts, since the coolant penetrates better and the slurry is removed more efficiently through the gaps between the segments. Segmented blades for cutting glass are usually used between 16 to 32 diameter.
For cutting small blocks of optical glass it is normal to use saw benches equipped with segmented blades of 16 to 20 diameter with a hard bronze bond around 60/70 US mesh. Operating at a cutting rate of 5 to 16 in2/min about 100 to 1600 ft2 of surface can be cut, according to the type of glass. Blade cost in this cause are about $0.09 to $0.11 centers per ft2.
By same token 16 diameter segmented blade can usually cut at rate of 40 in2/min 5 times higher, saws about 320ft2 of surface.
diamond blades for cutting thick glass >>>
SAWING OF FLAT GLASS
or more commonly know as sheet glass, or plate glass is widely used
for the architecture industry. This is used for glass doors, shower
doors, transparent walls, windows displays, and etc. Sawing flat glass is restricted mainly to certain special problems, for example cutting wire reinforced rolled glass. Here is an example of this applications.
Material: wire reinforced glass sheet 0.25 thick wire reinforcement 0.02 to 0.04 mesh 0.5
Blade: continuous rim diamond blade 14 diameter 16 concentration 100/120 US mesh, bronze bond
Cutting rate: 3.6 in 2/min = 10/47 cuts/hr
Life: about 20 working days = about 120 ft2 surface cut
Cutting reinforced glass would be relatively simple, if it were not for the internal layer of plastic to be sawn. Thin layers of the material are easy to cut, but with thick layers the lower edge has a tendency to shatter since the plastic layer is resilient. Thickness of 0.8in to 1.0in must therefore be sawn in several steps. Blades used are mainly 10 in in diameter with continuous rim.
recommended diamond blades
for cutting flat glass >>>