A diamond disc is a widely used tool among construction professionals for cutting various materials. Diamond discs are blades with a steel centre and a crown-like edge formed by a metal alloy with diamond particles, hence their name. But do we really know how to tile and use them? We explain it in this article.
Diamond Disc: What it is and What it’s Used for
First, we need to understand that these discs are abrasive tools that which cut through tile materials using the diamond particles. These diamond particles are surrounded by a metal alloy called a binder.
The function of the binder is to hold the diamond particles until they wear out or break. As the binder wears out, it allows more surface area of the diamond to be exposed. Eventually the diamonds become worn, and the blade becomes blunt.
This function of the binder is crucial. If it is not resistant to abrasion, it will result in tools with very fast and high-quality cuts but with a short lifespan. On the other hand, if the disc is very resistant to abrasion, it will not replenish the worn-out diamond particles. Consequently, the tool loses its cutting power.
It is then said to be “closed,” smooth, or “dull,” needing to be revived with a cleaning block to continue working.
Diamond Discs: How to Choose It
At RUBI, we have a wide variety of diamond discs. To choose the right one that suits our needs, we must consider the following factors:
1. What material we are going to cut
As we mentioned earlier, each material has different hardness and difficulty. In this case, we will need a disc and binder that adapt to the material we are going to cut so that we always keep the diamond on the surface of the binder and get a clean cut.
At RUBI, we make it very easy, and that’s why we have different colours of discs for the different materials we can cut.
2. Straight cuts vs Mitre cuts
It is not the same to make a mitre cut as a straight cut. At RUBI, we have special discs for mitring.
This type of cut has very high lateral pressure, and not just any disc will give us a good cut. We will need a sufficient thickness so that the diamond disc does not get damaged. Additionally, the use of mitring flanges will aid in mitre cuts to ensure the cut is accurate.
3. Types of diamond bands
The band of the diamond disc can have various finishes. The most common are continuous, segmented, turbo viper, or J slot discs.
Continuous: discs with a continuous diamond band. Generally used to achieve a finer finish on jobs that require more delicacy in the cut. Their cutting speed is lower.
Segmented: discs with a segmented diamond band (separated by spaces) to cut materials like brick, stone, granite, etc. They offer the maximum cutting speed. However, the finish is rougher.
Turbo Viper: discs with a serrated diamond band. They are characterized by having a higher cutting speed than continuous edge discs and a better finish than segmented edge discs.
J Slot: Discs with a J Slot band are designed to cut high sped on hard materials. Specifically for straight cuts on porcelain tiles.
4. Diamond Discs diameter
There are diamond discs of different diameters on the market. The diameter of the disc will offer us a different cutting depth.
We must always consider that we need to adapt the disc to the cutter we will use. For example, a DC- 250 Python uses a 250 size blade. Whereas a TC-125 G2 will use a 125 size blade.
5. Types of cut
The cutting mechanics with diamond discs lead to high temperatures, which results in two types of cuts depending on the cooling: wet or dry cuts.
Dry cut: this type of diamond disc does not need lubrication or cooling with water (although it can also be used with water). The tool works with the only cooling produced by airing. Generally, this type of cut will be performed with angle grinders.
Wet cut: this type of diamond disc is cooled with water to lubricate and keep the disc’s temperature stable during cutting. Additionally, it facilitates cleaning the diamond disc and evacuating the dust produced in the process. This offers a longer-lasting and much cleaner and more professional cut. This type of cut is usually performed with electric cutters.
Diamond Discs: How to Use It
Before using your diamond disc, check that it is suitable for the material you are cutting. It is also important to check that the disc has no cracks or defects, as this can result in a shattered blade when used.
Now, make sure the disc is correctly mounted and firmly fixed. Verify that the bearings and shaft of the grinder or circular saw are in good condition. Consult the manufacturer’s machine instruction manual for proper maintenance.
It is recommended to respect the maximum working speed of each disc diameter, as indicated by the manufacturer. Working with a variable speed grinder, which is corded, will allow you to achieve this.
Final Tips
While it can be confusing that different blades can be used wet or dry, it is important to remember that a dry blade can be used dry or wet, but a wet blade must always be used wet. Never use a wet cutting disc dry. The addition of water as a cooling aid will not damage the blade. But, if the blade needs water and it is used dry, this can result in the blade breaking during use.
Lastly, here are a few more tips and tricks to help you achieve the best result when working with a diamond disc.
- Do not force the disc during cutting; we must allow it to set its own pace.
- Never work obstructing the cutting line or disc path.
- Allow proper cooling by letting the disc spin freely every few minutes; we should not make long or continuous cuts. The harder the material, the more often we should rest the blade.
- When making a wet cut, do not start cutting until the water flow is adequate.
In conclusion, remember that safety at work is paramount, and working with diamond discs is no exception.
Always use the appropriate safety equipment: goggles, footwear, fitted clothing, hearing protectors, and, when necessary, a mask. But, without a doubt, the correct use of the disc is essential to always maintain safety.
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