Diamond Saw Blade Segment With Side Protrusions for Lower Friction
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Solution Overview
Problem
Current diamond tools for cutting hard materials like concrete and stone face inefficiencies in cutting speed and segment lifetime, with high lateral friction and dust/slurry accumulation issues.
Innovation Solution
The development of cutting segments and saw blades comprising a homogeneous mixture of metal powder and diamond granules, with protrusions extending laterally to reduce friction and promote dust/slurry evacuation, and wear indicator grooves for monitoring tool wear, allowing for efficient and cost-effective manufacturing and improved cutting performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional diamond tools are used for cutting hard materials, then cutting operation can be performed, but lateral friction is high and dust/slurry evacuation is poor
Solution Approach 1:
The cutting segment is divided into multiple functional zones: a cutting surface with diamond granules for abrasive cutting, and protrusions extending from side surfaces that act as separate elements for reducing lateral friction and promoting dust/slurry evacuation. This segmentation allows each zone to perform its specific function optimally.
Solution Approach 2:
Different regions of the cutting segment have different properties: the cutting surface has high diamond concentration for effective cutting, while the protrusions have reduced diamond content and optimized geometry for minimizing lateral friction. This local differentiation of properties resolves the contradiction between cutting effectiveness and lateral friction reduction.
2Duration of action of stationary object
If traditional cutting segments are used, then manufacturing can be performed, but segment lifetime is limited due to lateral wear
Solution Approach 1:
The protrusions are designed in advance to serve as sacrificial elements that protect the main cutting segment body from lateral wear. By providing this preliminary protection structure, the lifetime of the cutting segment is extended as the protrusions absorb the wear damage before it reaches the main segment.
3Reliability
If diamond granules are attached one-by-one to cutting segments, then cutting performance can be maintained, but manufacturing cost and complexity increase
Solution Approach 1:
The manufacturing process merges the attachment of diamond granules into a single molding step where diamond granules are incorporated into the metal matrix during cold pressing. This combines multiple operations (mixing, attaching, forming) into one efficient process, significantly improving manufacturing ease while maintaining consistent diamond distribution for reliable cutting performance.
Solution Approach 2:
The invention changes the manufacturing parameters from precision attachment methods to powder metallurgy cold pressing. By controlling parameters such as metal powder to diamond granule ratio (90-97% metal, 3-10% diamond by volume), pressing pressure, and temperature, consistent cutting performance is achieved through a simple, efficient manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances cutting speed by up to 20% and extends segment lifetime by 10% compared to traditional methods, while maintaining consistent cutting force and reducing lateral wear, thereby improving overall cutting efficiency and operational efficiency.
Implementation Method 1
Since the whole cutting segment is formed by a single homogenous mixture of metal powder and diamond granules it can be manufactured in an efficient and cost-effective manner, e.g., by cold pressing the cutting segment.
Implementation Method 2
diamond tools for cutting hard materials such as concrete, reinforced concrete and stone
Data Source
AI summary
A cutting segment (110) for mounting onto a saw blade to provide an abrasive operation by the saw blade, the cutting segment comprising a body (200) having a cutting surface (210) facing in a cutting direction (C), and side surfaces (220) facing laterally (L) with respect to the cutting direction (C), wherein a plurality of protrusions (230) extend laterally from the sides (220), and wherein the cutting segment (110, 410, 510) constituted by the body (200) and the protrusions (230) is formed by a homogenous mixture of metal powder and diamond granules.