Reasons and solutions for wire saw diamond falling off

When cutting stone or concrete with diamond wire saws, the phenomenon of rapid diamond detachment from the wire can occur due to improper production or usage. This phenomenon is commonly referred to as "diamond loss." There are several factors contributing to this issue:

Weak Bonding: The most common reason is insufficient bonding between diamond particles and the wire matrixmaterial. This can result from improper manufacturing processes, such as inappropriate sintering temperature or time, or the use of low-quality binders.

Incorrect Matrix Material: Different cutting materials require different types of matrix materials. If the chosen matrix material is not compatible with the cutting material, the diamond particles may not be securely fixed, leading to detachment.

Poor Diamond Particle Quality: The use of low-quality diamond particles can lead to detachment issues. Irregular shapes, low hardness, or uneven distribution of particles can contribute to detachment.

Incorrect Cutting Parameters: Excessive cutting speed, cutting depth, or cutting pressure can cause premature wear or detachment of diamond particles.

To address these issues, consider the following measures:
Optimize Manufacturing Process: Ensure strong bonding between diamond particles and the matrix material. Proper sintering conditions and duration can enhance bonding strength.

Select Appropriate Matrix Material: Choose the matrix material based on the hardness and characteristics of the cutting material to ensure secure bonding of diamond particles.

Use High-Quality Diamond Particles: Utilize high-quality diamond particles with regular shapes, high hardness, and even distribution to enhance adhesion.

Adjust Cutting Parameters: Set appropriate cutting speed, cutting depth, and cutting pressure to avoid excessive wear and detachment.

Use Suitable Coolants/Lubricants: Employ suitable cooling and lubricating agents during cutting to reduce friction and heat, minimizing the risk of particle detachment.

In conclusion, by optimizing manufacturing processes, selecting proper materials, adjusting cutting parameters, and employing appropriate operating practices, the issue of diamond detachment from diamond wire saws can be effectively addressed, leading to increased tool lifespan and cutting efficiency.