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Precision Diamond Saw / Wafering Blades Case Studies & Application Examples
Fully automatic Precision Sawing machines usually cost thousands of dollars. Yet, most advanced material facilities very rarely require the functionality of high cost, automatic sectioning saws. SMART CUT™ series of Precision Diamond Saws have been designed to provide the material researcher or engineer the same capabilities they would expect from high cost automatic sectioning saws, at fraction of the price. Start Saving Money Today! Below is a small example of applications, on witch SMART CUT™ Precision Diamond Saws are used day to day:
Customer saved Money and Time using SMART CUT 4002 Precision Diamond Saw. view SMART CUT 4002 VIDEO DEMONSTRATION (click on pictures below to view video)
Cutting Speed: customers polyethylene sample was sectioned at approximately 20 seconds. Surface Finish: a smooth cut was produced, with almost no burs on edges. Conclusion: SMART CUT 4002 can meet customers objectives in sectioning various size hard to machine plastic samples in matter of seconds, while still preserving material true micro structure.
Cutting Speed: customers polyethylene sample was sectioned at approximately 1:43 minutes. Surface Finish: a smooth cut was produced, with almost no burs on edges. Conclusion: SMART CUT 4002 can meet customers objectives in sectioning various size hard to machine plastic samples in matter of seconds, while still preserving material true micro structure.
Cutting Speed: customers quartz substrate was sectioned at approximately 29 seconds. Surface Finish: a smooth cut / surface finish was produced, with almost no visible chipping. Conclusion: SMART CUT 6001 can meet customers objectives in sectioning optical glass / quartz in matter of seconds, producing smooth surface finish & superior quality cut compared to other or traditional diamond cutting methods.
Cutting Speed: customers steel tube was sectioned in 11 seconds. Surface Finish: a smooth cut / surface finish was produced, with almost no visible burrs. Conclusion: SMART CUT 1004 diamond cut off saw can meet customers objectives in sectioning metallic materials in matter of seconds, producing smooth surface finish & superior quality cut, and minimal kerf / loss of material compared to other or traditional abrasive cutting saw & blade cutting methods.
Case
Study No. 2 A small rod of 100 steel: 6
chromium 15mm in diameter by 35mm in length was obtained for cutting
tests. Three cuts were made to evaluate cutting time, surface finish, and
accuracy of the cut (parallelism) using different diamond wheels. The surface of
the part following cutting was inspected using an inverted optical microscope at
low magnification to qualitatively compare surface roughness. The width of the
sample following cutting (the thickness) was measured to determine if any
significant variation was observed in the specimens. Finally, a comparison of
cutting times was made to compare the wheel cutting efficiency as well. The
sample rod material was cut using similar conditions for each diamond wheel. The sample was mounted onto the Model 650 Low Speed Diamond Wheel Saw using a Model 65006 Vise sample holder. A water-soluble coolant was used to prevent excess heating during the cutting process, and was replenished after each cut. Cutting load was applied to the specimen directly onto the arm mechanism, and the counter-balancing weight was used to prevent wheel binding during the cutting process. A total cutting load of approximately 600 grams was used with the diamond wheel saw during each cut, and dressing of the blade was done periodically every hour during the cutting process. |
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Cutting times and thickness variations of diamond wheels cutting 100 Steel: 6 Chromium sample
| Wafering Blade Type | Cutting Time | Thickness (mm) | Variation (mm) |
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SMART CUT™ Diamond Wafering Blade |
8 hours | 1.940 – 2.070 mm | 0.130 |
| Conventional Diamond Wafering Blade | 13 hours, 12 min | 1.370 – 1.540 mm | 0.170 |
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Wafering
Blades Tested: New
Generation Metal Bond Diamond Wafering Blade with SMART CUT technology Mesh
Size: 120 |
Conventional Diamond Wafering Blade: is a well known "Brand Name" Diamond Wafering Blade in metallography, material science, & sample preparation industry. |
Cutting / Sectioning Materials with a High Metallic Content
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Case Study No. 3 Product:
10” x .040” x ½” New Generation metal bond Diamond Wafering Blade
with SMART CUT™ technology Application: Zr, Nb, Ti, Hf, and their alloys.
These are very tough, ductile metals. Saw Used: Struers Discotom 5 abrasive
cut-off saw Blade Life: 4 months Customer Comments: "We found that it worked well for cutting all of alloys and pure metals. It worked extremely well for sectioning carbide inclusions in Zircaloy. Before using your blade, we have had little success sectioning these types of samples." |
Case Study No. 7 Material: cobalt chromium Specimen Size: 4.0" Saw: South Bay 650
Cutting Speed SMART CUT™ New Generation Metal Bond Diamond Wafering Blade: 8 hours conventional metal bond diamond wafering blade: 13 hours Conclusion: SMART CUT
Diamond Wafering Blade cut Cobalt Chromium 1.62 times faster
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Case Study No. 4
Application: sectioning a client part
consisting of a thick stainless steel disk bonded by a proprietary process to an
alumina ceramic insulator.
Customer Comments: “ I had previously mounted this combo in epoxy and attempted to cut it on another manufacturer's low speed wafering saw using both their diamond blade and a wafering blade they had recommended for cutting metal. Both blades did well on the ceramic but even with constant dressing the cutting rate in the metal portion of the sample was infinitesimal and I gave up the effort after a whole day of effort. Your blade cut the same sample in approximately 15 minutes on the surface grinder and rates in the stainless steel portion were only slightly slower than in the ceramic. "
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Case Study No. 5
Cutting Speeds in Minutes Smart Cut™ Wafering Blades: 1.51 Conventional Blade: 5.15 Conclusion: SMART
CUT™ New Generation Metal Bond Diamond Wafering Blades
cut Copper 2.32 times faster |
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Case Study No. 6
Cutting Speeds in Minutes Smart Cut™ Wafering Blades: 5.59 min Conventional Blade: 13 min Conclusion:
SMART CUT™
New Generation Metal Bond Diamond Wafering Blades cut Copper 2.32 times
faster |
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Compare Our Performance & Prices
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First company to develop SMART CUT™ technology, advanced technology that redefines the standard in cutting and drilling.
Diamonds are oriented inside matrix, so that every diamond is better able to participate in drilling action. SMART CUT open bond bond design makes sure 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. Find out more..
What you should know before you buy your next diamond blade?
UKAM Industrial Superhard Tools Division of LEL Diamond Tools International, Inc.
28231 Avenue Crocker, Unit 80 Valencia, CA 91355 Phone: (661) 257-2288 Fax: (661) 257-3833
e-mail: lel@ukam.com
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