Common cutting issues with diamond saw blades during stone cutting

In general, when using diamond saw blades for stone cutting, we often encounter various issues, including common ones like blade burning, sparking, blade jumping, segment loss, and lack of sharpness. Let's discuss them in detail below!

Blade burning: This is specifically manifested as the blade tip portion turning red or even black, with the temperature rising rapidly and unable to decrease. The main possible causes for this are:

1. The saw blade matrix is too hard, the diamond grit is improperly exposed, or the diamond exposure height is insufficient;
2. The cutting linear speed is too low during stone cutting, and the depth of cut is too high.
3. Insufficient blade rigidity, causing blade deflection.

Sparking: Also known as fire streaking, this mainly refers to the blade emitting sparks during cutting. In severe cases, it can cause obvious black cutting marks on the slab surface. Sparking is mainly caused by the following reasons:

1. Improper diamond distribution, where the diamond-scarce areas cannot cut through the stone properly.
2. The matrix being too hard or too soft can also lead to this issue. Too hard causes slow matrix wear, too soft causes rapid diamond loss.
3. Abnormal diamond grit size or concentration can also cause this problem. In general, sparking occurs mainly due to the intense cutting action between the matrix and stone, indicating issues with the blade tip matrix or diamonds.

Blade jumping: This refers to instability during cutting, with the blade jumping, swaying left and right, or bouncing up and down. The main cause is improper diamond exposure leading to jumping, while the matrix's holding strength determines the jump amplitude. Sudden changes in the stone structure can also cause blade jumping.
Segment loss: Segment loss is very common, with many potential causes, including:

1. Welding issues during segment attachment.
2. Stone being too hard for the blade's sharpness.
3. Matrix being too soft or too hard.
4. Excessive depth of cut.
5. Insufficient blade rigidity.
6. Inadequate coolant flow causing overheating.
7. Low or uneven diamond concentration.
8. Non-uniform material mixing during sintering.

Lack of sharpness: This mainly manifests as reduced sharpness of the diamond blade during stone cutting, with slow cutting speed. If the downfeed rate is set too high, it can cause the motor current to spike. Blade dulling is mainly caused by temperature gradients, powder activity state differences, and uneven low-melting additive distribution during sintering, leading to organizational and mechanical property changes -- these are microstructural issues. Additionally, the accumulated cutting heat weakens the fused segment's properties. Vibrations and impact forces transmitted through the diamonds also degrade the matrix's holding strength, causing premature cutting fatigue. Of course, there are other causes of blade dulling, such as insufficient diamond concentration, improper diamond grit ratio, inadequate matrix holding strength, etc., all leading to slower cutting speeds.