The Ultimate Guide For Using OneStop Diamond Saw Blades

| Visit:567

If you read this book before purchasing OneStop Diamond Tools, you will have a better understanding of which diamond tools to choose. If you read it during use, you will be able to use our diamond tools more efficiently and save on production costs.

Our company's products are divided into categories that include sawing, drilling, milling, grinding, polishing, etc., based on the needs of our customers and our years of experience.

According to the above categories, this book provides detailed instructions on how to purchase, install, use correctly, and troubleshoot any problems you may encounter.

Thanks to the engineers and technicians of OneStop Diamond Tools Company for their hard work, and to the stone industry and construction experts who provided relevant information.

Your trust and support are OneStop's eternal goal!

How to selcet the blank blade?

1. Selecting according to the saw machine

Component blanks for circular saws are selected according to the diameter of the saw. For middle circular saws, a ф700-ф1800mm blank is used, and for big-size circular saws, a blank ф1900 or larger is needed. For single saws, using a normal blank is sufficient, but for multi-blade saws, exclusive multiple blanks must be selected, with 2pcs-40pcs per blade to be installed.

2. Selecting according to the material

A narrow-slot blade with a narrow-slot blank is a common type of blade that ranges from 700mm to 800mm. It is often used in edge cutting and small-size plate cutting, and is especially suitable for cutting granite and marble. While wide-slot blades are characterized by high speed, high efficiency of cooling and chip-flushing, and the long lifespan.

3. Selecting according to the characteristics of material, the working surroundings and blades' capability.

When selecting frame blades for hard stone, such as Indian-red and South-African-red, it is best to use one piece of big blade and one piece of small blade, or one big and one middle and one small. For mid-hard stone, select frame blades comprised by two big and two small blades, or three big and three small. For soft stone, select the frame blades comprised by five big and five small blades.

How to select diamond segments?

The term "segment" refers to a diamond segment. In masonry, sawing, cutting, grinding, and polishing work all rely on the properties of diamond, such as its high hardness, high intensity, and high wear resistance. The blank is used as a support. Diamond segments usually cost 12.5% of the total cost of the cut stone, so it is important to use and choose them wisely.

The width of a segment can be grouped by its error band. The error band for a given segment should be kept within 0.05 mm to maintain consistency across blade segments.

When cutting stone, the diamond crystals do the majority of the work, while the metal bond holds them together. Diamond crystals would be exposed at a certain height, generally, at the 20%-60% height of the crystal, it depends on the stone. Different stone has a different requirement for the lowest height exposed.

The kerf cut by the blade is the result of the cutting action of the diamond crystals.

What is blade durability? Blade durability, or blade lifespan, refers to the number of square meters of stone that a blade can cut before the diamond layer wears off.

The quality of a saw blade is judged by the surface quality of the material it cuts, including the level of the surface, the smoothness, and the lack of flaking. Poor surface quality, coarseness, and flaking all indicate a poor quality saw blade.

The cutting efficiency is defined as the acreage of stone that is cut within a certain unit of time. This index is important for determining the blade's performance. The cutting efficiency can be affected by factors such as the cutting depth, cutting speed, and cutting time.

There are four main factors that contribute to cutting efficiency: 

1. diamond concentration is a key factor in determining the lifespan of a cut. Too high or too low a concentration can adversely affect cutting efficiency. Finding the balance point between users' requirements and economic factors is essential.

2. Bond is determined by the type of stone, the concentration of stone, the parameters of saw machinery, and the cooling conditions. Sometimes operator performance should also be taken into account.

3. The value of diamond grit depends on the hardness of the cut stone and other factors. The harder the cut stone is, the smaller the grit is and the more powerful the cutting is.

4. Line speed is affected by the hardness of the stone. Softer stones have higher line speeds, while harder stones have lower line speeds.

How to weld the diamond segments on the blank blade?

1. The process of welding segments onto the blank is actually a heat-treatment process for the teeth of the blank. Some degree of damage to the blank structure is inevitable. It is therefore very important to minimize this damage as much as possible.

2. The welding temperature typically ranges from 600℃ to 800℃. Using an improper temperature can cause additional damage to the blank or segment.

3. We recommend using high argentiferous solder for silver soldering, which should have a percentage of 35% or higher. Additionally, choosing low-temperature and eutexia solder will help shorten the soldering time.

4. For small-size blade welding, the diameter of the flange should be increased, even if it means the rim reaches the bottom of the slot.

5. For large-scale blade welding, it is recommended to use a cooling method to minimize the heat effects.

6. When using fans to ventilate the work environment, please ensure that the wind direction is parallel with the diameter of the welded blade.

7. In order to intensify the welding between the blank and the segment, the non-working layer on the segment should be ground according to the arc shape of the blank teeth. However, if there is no non-working layer on the segment, the teeth of the blank should be ground.

8. The positioning and dimensions of segments and blanks should be symmetrical in order to create a flat surface.

9. To ensure optimal welding results, it is recommended to apply a soldering paste or fluid to the interface of the blank and segment. This will eliminate any oxide present on the interface and make welding easier.

10. To avoid overheating, high-frequency welding should be taken at an interval of four to six teeth.

11. It is forbidden to use flame welding.

12. To avoid distortion occurring on the blank, the just-welded blade should stay on the welding frame for at least 2 hours before it can be taken down and suspended.

13. Generally, a ф1600mm blade should be suspended more than 10hrs after being welded before being put into sawing, otherwise, the damage would be made to the blank, and the lifespan of the blade would be shortened.

14. After welding, the blade should be cooling down unaffectedly. It is forbidden to use water or other cooling media. Otherwise, distortion follows.

15. To avoid distortion, blades should be put flat, or stored on the exclusive axis.

How to select the right diamond blade?

  1. When selecting a diamond blade, it is important to consider the factors that will affect its cutting performance. This includes the blank and segments that are welded onto the blade. By paying attention to these details from the beginning, you can achieve a higher level of efficiency and lower your working costs.
  2. The performance of a blade must be suitable for the nature of the stone being cut. The factors that affect the performance of a blade include the intensity, grits and concentration of diamond, as well as the hardness and wearability of the bond matrix. While, the nature stone is affected by factors such as hardness, density and abrasiveness.
  3. When choosing a blade, take into account the specifications and quality of the material being cut. Generally, the blade’s diameter should be at least three times the width of the slab being cut. In addition, the blade’s type should be appropriate for the desired cut, e.g. narrow-slot blade for smooth-surface cutting, thin-width cutting or fragile-material cutting. Conversely, wide-slot blade for coarse-surface cutting or thick-material cutting.

Debug guide for saw machine

1. What is the reasoning behind the design of a saw machine? The saw blades fitted on the main axis rotate, while making a linear reciprocating movement on the track of the crossbeam. As for a single-arm saw machine, the reciprocating move is completed by the working device on it. When cutting the stone, the blade presses, grinds, and cuts the stone, then the kerf appears.

2. It is crucially important to ensure that the saw machine is running smoothly with low noise and vibration, and that each part of it is highly precise. Otherwise, damage, breakage, or unconventional weariness may occur.

3. The power of a saw machine's main engine is decided by the diameter of its blade and the type of stone it is cutting. Here are some recommendations:

Type of Stone Diameter of Blade General linear speed
(mm) Low Power(kw) High Power(kw)
Marble 200-250 1.5 3.7
300-400 5.2 9
450-550 7.5 14.5
600-650 9 18.9
700-750 13.4 29.9
800-900 16.7 37.3
1000-1100 22.4 48.5
1200-1300 29.9 59.7
1400-1800 44.8 67.2
1900-2200 48.5 74.6
Granite 200-250 1.5 3
300-400 3.7 7.5
450-550 9 13.4
600-650 13.4 14.9
700-750 16.7 26
800-900 18.7 29.9
1000-1100 22.7 33.6
1200-1300 29.9 44.8
1400-1800 41 59.7
1900-2200 44.8 67.2

4. It is recommended to change the lubricant oil every 4-6 months.

5. Before starting the saw machine, it is important to check and lubricate all joints, moving interfaces, and rotating joints. This will ensure that the machine runs smoothly and safely.

6. It is important to keep all joints and interfaces lubricated after each work day. This will help prevent wear and tear on these components.

7. Periodically check the bolts to avoid looseness, and check the trigonal belts for the appropriate degree of tightness.

8. We should clean the stone powder regularly, and flush the workbench and work area.

How to install diamond blades?

1. Cleansing: The main axis and flank should be cleansed and moved off rust, dirt, smear, etc, with fine sand-paper.

2. Removing burs: In the case of drilling the core in blades for installation, the burs on the core should be removed by grinding tools and coarse sand paper.

3. When installing a blade on a sawing machine, ensure that the direction of rotation of the machine is the same as the arrow printed on the blade. Furthermore, always keep the blade installed in the same direction. Otherwise, the lifespan of the blade will be shortened.

4. Flanges are used for positioning, tightening and torque-transmitting purposes. The diameter of a flange is generally one-third of the diameter of a blade, but it is recommended to choose the largest diameter of a flange that still allows for the desired cut size. Here are some recommendations:

Diameter of Blade (mm) Diameter of Frank (mm) Thickness of Frank (mm)
200 80 12
250 100 12
300 120 12
350 140 15
400 150 15
450 160 15
500 170 18
600 180 18
700 200 20
900 250 20
1100 250 20
1200 300 25
1400 325 25
1600 375 30
2000 425 35
2200 435 35

How to Sharpen/open diamond saw blades?

1. The vast majority of diamond segments are sintered in a mold, with a maximum of 16 segments per mold. However, a single blade can have tens or even hundreds of segments, which explains why segments of different sizes can be found on the same blade. This also provides the justification for why a new blade needs to be edged/opened before use.

2. The new segments just produced are enwrapped by the metal bond matrix, and should be edged/opened before putting into sawing.

3. It is recommended that blades be edged/opened on the edger/open-machine before installation on the saw machine. This is done in consideration of the edging/opening efficiency and the quality of the blade.

4. After installation, the unopened blade should be sharpened with a strong abrasive material such as fire-resistant bricks before formal use. Generally, after a few cuts, the diamond edge will be exposed and can be used.

5. It is recommended to use firebrick (and so on) to restore the sharpness of the blade's edge.

How to cut stones with diamond saw blades?

1. For the debut use of the new blank (or blade), it is recommended that you let it rotate load-freely for about 30 minutes. This will help to further eliminate the negative affects of welding on the blank, and will keep the blade's stability of quality and prepare it for high-speed rotation.

2. The stone block must not be less than 0.5 cubic meters, and should be placed firmly, with the bottom surface being blocked by square wood, so as to ensure the stability of the workbench car and the stone block, without shaking or trembling.

3. Before cutting, be sure to adjust the cutting range according to the dimension of the block. The range should be located within the effective scope. Hold the blade 10-20mm above the block being cut. There should be 20-40mm allowance between the bottoms of the block and kerf. To prevent bumps, make sure the blade is more than 150-200mm away from the kerf before moving the blade.

4. Before cutting into a block, ensure that the blade is running at its full speed. It is forbidden to stop the blade while it is still inside the kerf/block.

5. If the block begins to shake while you are cutting, please stop the cutting immediately. Once you have secured the block, you may resume cutting. It is forbidden to move the block while you are cutting.

6. If you experience a slowdown in the blade or clamping, please take adjustment measures in a timely manner. This may be caused by a slide in the belts, looseness of the tightening nut, too deep of a cut, or a large cutting speed.

7. Linear speed should be selected based on the hardness and abrasiveness of the stone being cut. The table below provides recommended line speeds.

Type of Stone Hard Granite Middle-hard Granite Soft Granite Hard Marble Soft Marble Sandstone
L-speed (m/s) 25-30 30-35 35-40 40-45 45-50 50-65

Remarks: Increasing the cutting efficiency at a low line speed will decrease the lifespan of the product.

8. The cutting feed should depend on the material to cut. When cutting depth is constant. there will be different speeds for different materials. Cutting at a bigger feed will make diamond wear extra, even desquamated, and expedite blade's abrasion, while, a small feed, will invalidate the procedure of blade's self-sharpened. Then bluntness, skid and even cutting shut-down would occur. The feeds corresponding to different materials are tabled as below,

Cutting Feed For Common Material ( In the case of 6mm cutting depth)

Material granite marble concrete corundum quartz /porcelain
Cutting Material(mm/min) 200-500 1000-2000 250-400 70-125 250-500

9. The depth of the cut should be determined based on the hardness of the material and the performance of the blade and machine. For medium-hard materials such as marble and limestone, a single cut should be sufficient, while hard or high-abrasive materials such as granite and sandstone may require multiple cuts.

10. For stabilizing the cutting, it is recommended to use parallel-cutting, which refers to the same direction between blade and stone feed. It is because counter-cutting, which on the contrary, refers to the opposite direction, will push up the stone. The counter-cutting depth should be one-third to half of the depth of parallel-cutting.

11. In conclusion, the best way to cut soft stone is to use a small feed at a deep cut, while for hard stone, it is best to use a large feed at a shallow cut. The purpose of this is to achieve a high level of efficiency, good output quality, and a long lifespan for the blade or blank. For multi-blade cutting, recommended as follows,

Cutting Parameter Soft Marble Hard Marble Soft Granite Mid-hard Granite Hard Granite
Linear speed(m/s) 45-50 40-45 35-40 30-35 25-30
Depth(mm) 300 300 4-5 3-4 1-2
Feed (mm/min) 120-140 60-70 60 60 60

Cooling & Lubricating

1. To improve cutting efficiency and reduce cutting costs, it is necessary to select the appropriate coolant or lubricant to improve cooling and lubrication in the cutting process.

2. The coolant or lubricant can play an important role in flushing away the cuttings and lowering the cutting temperature. Therefore, it is essential to supply sufficient coolant or lubricant to the blade in order to obtain high-quality cutting results and minimize blade consumption.

The amount of coolant is recommended as follows (Usually, the cooling pressure should be over 0.2Mpa):

Diameter of blade (mm) Amount of water (L/mm) Diameter of blade (mm) Amount of water(L/mm) Diameter of blade (mm) Amount of water(L/mm)
450 10-15 900 30-40 1600 60-70
500 15-20 1000-1100 40-50 1800 70-80
600 20-30 1200 50-60 2000 90-100

Causes and Remedies For The Common Problems of Diamond Segments

Problems Causes
Poor sharpness and low square meters (lifespan)

Embodiment:  cutting feed decreased, the electric current of the motor increased, while the cutting speed lowerd, even abnormal noise and flutter, etc.
  • the density of diamond is too high
  • insufficient voltage ( less 360 V)
  • insufficient power of the cutting machine ( less 22KW)
  • soft or uneven blank, flutter
  • more than one of the belts of the cutting machine loosened
  • unfastened basement for the material being cut
  • coolant too dense
  • worn or loosened spindle bearings of the machine
  • too much feed when cutting
Good sharpness, but insufficient square meters (lifespan)
  • comparative lower intensity of diamond, especially the big crystal of diamond
  • higher power for the cutting machine, or higher RPM of the spindle, which will wear diamond abnormally fast.
Good cutting with the upper-half part of segment, but low performance with the other half part of segment.
  • inferior quality of silver solder
  • too long welding time for the segment
  • too high temperature when welding
  • the oxidation of diamond and band matrix occurred on the lower half part of segment when it is overheated
Good cutting in the beginning, but poor performance following after few hours.

Embodiment: the total sharpness is insufficient, while in the beginning is an illusion.
  • unlevelness of segments occurred when welding, impact phenomenon following in the beginning
  • disappearance of impact phenomenon after cutting for a short time, when segments being worn, and sharp decrease of sharpness
Good cutting with the upper-half part of segment, but can't cut with the other half.
  • low sharpness of the segments initially
  • worn and softened blank attributing to too much recycle
Uneven segment wear.
  • worn spindle bearing
  • unlevel installation of blade
  • unlevelness occurred when welding
  • too soft of the blank blade
Clamping blade

Embodiment: most occurred when the blade cuting half inside the stone
  • smaller width of segment (thinner segment)
  • inferior quality of side parts of segment
  • worn spindle bearing
  • unlevelness of the blank

Causes and Remedies for Abnormal Noise Problems When Cutting

Fault Types Causes Remedies
Saw machine's malfunction Abnormal noise in gear case Bigger clearance of bearings Adjustment
Worn partially bearings Replacement
Overload Adjustment
Loosened headstock or gear case Adjustment
Loosened bearings Adjustment
Abnormally high temperature of the main axis Smaller bearings clearance Adjustment
Bad lubrication Adding oil
Overload Adjustment
Bigger bearings diameter Adjustment
Worn bearings Replacement
Oil leaking in headstock Worn oil seal Replacement
Remarks: Abnormal noise and high temperature will occur if not eliminate the oil leaking problem.
Segments and blank misfunction Shrillness Blunt segments Opening
No diamond exposed Replacement
Softer bond matrix and diamond pop-up Replacement
Insufficient coolant Adding
Uneven welded segments Adjustment or Replacement
Abnormal noise with heavy friction Softer blank Adjustment
Vibration of blank or blade Rounding

Causes and Remedies to Some Common Problems

Problem Cause Remedy
Short Cutting Life Using a wet cutting blade for dry cutting. Use a dry blade instead.
Insufficient supply of water to the blade. Make sure water hoses are clean and free from any blockages.  Supply sufficient water flow to both sides of the blade.
Using a blade with the wrong specifications. Use a blade with the proper blade specifications as recommended by the manufacturer.
Worn blade arbor and/or misaligned machine spindle. Replace blade and/or repair machine.
Blade Won't Cut The bond matrix is too hard for the material being cut. Use a blade with a softer bond matrix.
The material being cut is too hard for the blade. Dress or sharpen the blade by cutting some soft abrasive material to expose diamonds.  If continued dressing is required, this indicates that the bond matrix is too hard and a blade with a softer bond matrix should be used.
Insufficient power to permit the blade to cut properly. Use correct voltage and adequate horse-power.
Diamonds Pop Out Excessive porosity in bond matrix. Use a different bond matrix.
Insufficient supply of water to the blade. Make sure water hoses are clean and free from any blockages.  Supply sufficient water flow to both sides of the blade.
The blade vibrates during cutting. Attach the blade to flange firmly and make sure machine condition is properly controlled.
The bond matrix is too soft to hold diamonds. Choose a harder bond matrix.
Using a wrong arbor hole. Check proper size of bore.
Excessive work time. Reduce and control work time.
The material being cut or the machine is not held firmly. Maintain a firm grip on the material and secure the machine firmly.
Blade Wobbles The blade is mounted on a damaged or worn machine. Repair or replace the machine.
The blade is not tensioned properly. Have the manufacturer correct the tension on the blade
The blade is run at an improper operating speed (RPM). Make sure the blade is operating at the manufacturer's suggested RPM.
Loss of Segments The material being cut or the machine is not held firmly, which then causes the blade to twist or jam during cutting.  Maintain a firm grip on the material and secure the machine firmly. 
The blade is not cutting in a straight line. Align the machine properly to avoid twisting the blade in the cut.
Insufficient supply of water to the blade.  Make sure water hoses are clean and free from any blockages.  Supply sufficient water flow to both sides of the blade. 
Defective flange causes the blade to flutter in the cut. Replace the flange.
The bone matrix is too hard for the material being cut. Use a blade with a softer bond matrix.
Core Warpage The steel core has been overheated. Supply sufficient water and make sure water pump is producing sufficient water.
The blade is spinning on spindle. Check spindle and arbor hole for damage.
The steel core is rubbing excessively against the material being cut. Maintain a firm grip on the material and secure the machine firmly.
The blade is run at an improper operating speed (RPM). Make sure the blade is operating at the manufacturer's suggested RPM. 
Uneven Segment Wear Insufficient supply of water to the blade. Make sure water hoses are clean and free from any blockages.  Supply sufficient water flow to both sides of the blade. 
Defective machine which causes the blade to wear out of round. Replace bad bearings or worn machine spindle, or realign misaligned spindle.  Replace the machine if necessary.
The saw head misaligned. Check saw head alignment for squareness, both vertically and horizontally.
Cracked Segments The blade is too hard for the material being cut.  Use a blade with a softer bond matrix. 
Uneven Cutting The steel core is not flat. Have the manufacturer redo straightening and tensioning.
The material being cut or the machine is not held firmly Maintain a firm grip on the material and secure the machine firmly. 
Extreme Noise Insufficient supply of water to the blade.  Make sure water hoses are clean and free from any blockages.  Supply sufficient water flow to both sides of the blade. 
The material being cut or the machine is not held firmly.  Maintain a firm grip on the material and secure the machine firmly. 
Bad spindle bearings. Check bearings and replace them if needed.
The steel core is rubbing excessively against the material being cut.  Maintain a firm grip on the material and secure the machine firmly. 
Improper RPM and/or traverse speed, causing excessive work load on one side of the segments. Use manufacturer's recommended RPM and traverse speed.
Sparkling Insufficient supply of water to the blade.  Make sure water hoses are clean and free from any blockages.  Supply sufficient water flow to both sides of the blade. 
The cutting speed is too fast. Reduce the cutting speed.
The blade is too hard for the material being cut.  Use a blade with a softer bond matrix. 
Arbor Out-of-Round The flange is not properly tightened, causing the blade to either rotate or vibrate on the spindle. Wrench-tighten spindle nut to make certain the blade is adequately secured to prevent it from rotation or vibration.
Worn, bent or dirty flange which disallow proper blade mounting. Clean or replace the flange.

Get A Quote

If you are interested in our products and want to know more details,please leave a message here,we will reply you as soon as we can.