How to Determine When to Replace Diamond Tools? A Practical Guide to Extending Service Lifespan
Views: 5 Author: Site Editor Publish Time: 2025-02-13 Origin: Site
Diamond tools are widely used in stone processing, construction cutting, precision manufacturing and other fields because of their super hard and wear-resistant properties.
However, even diamond tools will gradually fail after long-term use due to wear, overload, or improper operation.
Determining whether tools need to be replaced in time can not only ensure work efficiency, but also avoid safety hazards caused by tool damage.
Below are key indicators and methods to determine the optimal replacement timing for diamond tools:
I. Visual Inspection: Assessing Wear Levels
1. Exposure Status of Diamond Grits
A. Normal Condition: Diamond particles are evenly distributed on the tool surface, and the edges of the particles are clear and sharp.
B. Replacement Signals: The particles are severely worn and flattened (the surface appears "mirror-like"), fall off in large areas, or the base metal is obviously exposed.
▶ Tip: Use a magnifier or microscope to inspect grit conditions, especially in high-frequency usage areas.
2. Dimensional Changes
A. Reduced Diameter (Blades/Drill Bits):When the diameter is reduced by more than 10%-15% of the original size due to wear.
B. Thinned Segments:
When the thickness is reduced by more than 20%, the structural strength of the tool may not be able to bear the load, which may easily lead to the risk of breakage.
3. Abnormal Damage Marks
A. Cracks or Chips: Visible cracks in the matrix or welded joints indicate overload or impact damage.
B. Deformation: Tools that are bent, eccentric, or have irregular edges can cause cutting deflections and increased vibration.
II. Performance Decline: Efficiency & Quality Indicators
1. Reduced Cutting/Grinding Efficiency
A. Extended Processing Time: Noticeably longer time required for the same material and thickness.
B. Increased Power Demand: Equipment requires higher power input or frequent pressure adjustments, often accompanied by motor overheating.
2. Cutting quality is not up to standard
A. Rough Surfaces: burrs and chipping appear on stone or metal incisions.
B. Accuracy Deviation: Drilling misalignment, curved cutting lines, or reduced product yield rates.
III. Use experience: Abnormal Signs Warning
A. Unusual vibration or noise: Intense shaking or screeching during operation indicates uneven wear or structural damage.
B. Overheating: Abnormal temperature rise (e.g., smoking/discoloration) in tools or materials requires immediate shutdown.
C. Changed Dust Characteristics: Coarser abrasive particles suggest ineffective material removal.
IV. Regular testing: Assessing Tool lifespan
1. Track Usage Hours & Workload
Establish replacement intervals based on manufacturer-recommended lifespan (e.g., cutting meters, drill counts) and actual conditions (material hardness, cooling methods).
2. Professional Testing Equipment
A. Hardness Tester: Verify diamond layer hardness compliance.
B. Dynamic Balancer: Ensure rotational balance to prevent high-speed operation hazards.
V. Tips to Extend Tool lifespan
A. Follow Operating Guidelines: Avoid dry cutting without coolant or excessive pressure.
B. Regular Cleaning: Remove debris from tool gaps to prevent clogging and corrosion.
C. Material-Specific Selection: Choose specialized tools for concrete, granite, glass, etc.
When does it need to be deactivated immediately?
If the tool is severely deformed, has a large area of teeth chipped, or has a cracked base, it must be replaced immediately, otherwise serious consequences may occur.
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