Manual welding diamond segment method

Diamond saw blade is a kind of diamond tool for cutting and grinding stone, reinforced concrete, ceramic tile, asphalt and other materials through the diamond segment of the sawtooth part. Generally speaking, due to the diversity of cutting objects and the uncertainty of construction conditions, the working conditions of diamond segments are often relatively harsh. In the face of high speed (high centrifugal force), high impact (the deeper the cutting depth, the faster the cutting speed, the higher the impact force), high resistance (the hardness of the cutting material is very hard), these place severe requirements on the welding of diamond segments.
In addition, with the continuous improvement of the cutting speed and feed rate of diamond saw blades, the requirements of diamond saw blades for the strength of the weld seam of diamond blades are also getting higher and higher. However, because some manufacturers or companies have not introduced new machinery, many manufacturers still use semi-automatic or complete flame welding to weld the diamond segment. This largely relies on manual proficiency to weld the segment, and it is still a main way for people to weld the diamond segment. So what are the methods of manual welding diamond segment? What problems should be paid attention to when manual welding? We can have a deeper discussion at below.

In terms of content selection before welding, silver soldering sheets should be used as much as possible, because silver-copper soldering sheets for diamond saw blades are better than phosphor-copper soldering sheets.

In terms of the performance of the welding rod, silver copper is added to copper to improve the fluidity of the welding solution and the mechanical properties of the welding position. Phosphorus copper solder is actually pure copper (phosphorus exists due to the smelting process, not deliberately added). And because of the low phosphorus content, this solder is brittle. If there is no special requirement, phosphor copper solder is generally used (because it is cheap). However, when there are some special welding operations (for example, the weldment and the welding fluid are not easy to melt, we call it non-stick welding rod), it is better to use silver-copper solder.

Manual welding should be performed according to the following methods.

1. Check the inner and outer diameters, thickness and number of teeth of the matrix according to the production requirements, and check the specifications, quantity and radian of the segment. Then grind the outer round chamfer of the base on the dressing equipment. Clean the substrate and the welding surface of the diamond segment with acetone, etc., and apply flux.

2. According to the specifications of the diamond saw blade in the construction requirements, stone factories need to select the corresponding welding piece. The width of the solder piece is generally 0.5~1 mm larger than the thickness of the substrate. When welding diamond saw blades with a diameter of more than 1500 mm, the thickness of the welding sheet is selected to be 0.25~0.30 mm; When welding saw blades with a diameter of less than 1500 mm, the thickness of the welding sheet is selected to be 0.15~0.25 mm.

3. Install the substrate, adjust the position, tighten the fixing screws, and put the cooling splint on. Adjust the diamond segment pushing device and segment clamp, adjust the welding temperature, heat preservation and cooling time according to the process requirements, and perform welding.

4. When using high-frequency equipment to weld saw blades, rotate the base at 180°C for each diamond segment to be welded symmetrically, so as to avoid annealing or local deformation caused by overheating of the base.

5. When weweld the gang saw, we need to weld the segments one by one to the specified position according to the tooth arrangement diagram. Generally, the row spacing has a fixed spacing, and a row spacing distributes 28-32 diamond segments. Of course, the number of segments should be considered according to the length and shape of the diamond segment.
6. After welding a saw blade, a self-inspection must be carried out. There are three main types of self-inspection methods, the first type: flatness inspection. The second category: detection of radial jump and end jump, which can determine the stability of saw blade cutting. The third category: that is to test the welding strength of the diamond saw blade. It is best to use a strength tester for testing, but most manufacturers will use diamond segment pliers to move left and right to test the welding strength.