LPI_Cutting_Training Module 0522.ppt
- 1. GENERAL PURPOSE CUTTING PART 1: DISCUSSION May 2022
- 2. This presentation is designed to serve as a stand-alone training piece, as well as act as a companion piece to Lackmond’s hands on diamond training program. Classroom instruction is important, but there is no substitute for hands on training to reinforce academic concepts. Contact your Lackmond representative to schedule hands-on training: 800-850-2044. Cutting course includes : • Cutting Blades OPENING STATEMENT
- 3. COURSE OVERVIEW Blade Overview • Performance differences between blade styles • Common terms and concepts • Undercutting / Undercut Protection • Blade Tensioning Tools Overview • Common features and important terms • Proper blade mounting • Starting / Operation of tool Hands on Cutting • Hard bonded blade on soft material • Hard bonded blade on hard material • Soft bonded blade on soft material • Soft bonded blade on hard material • Concrete blade on concrete with reinforcement
- 4. Blade features and how they impact performance: Familiarity with commonly used tools • Hand held, high speed saws • Walk behind saws • Masonry Saws Practical Application: Bond Discussion • Why is it so important to match blades to specific applications? • How do blades perform in various aggregate? Cutting through reinforcement • Hearing sound difference when hitting rebar • Feeling saw feedback change • Proper cutting technique KEY CONCEPTS
- 5. Diamond blades are grinding tools, NOT cutting tools When used correctly, diamond blades are self sharpening tools The exposed diamond on the blade segment grinds the material away. While the blade rotates and is pushed into the material, the exposed diamonds score the material and grind it into a fine powder. The exposed diamonds crack or fracture as they grind due to applied pressure and generated heat. As the segment wears down and the diamonds are consumed, new diamonds are exposed to continue the cutting process HOW DIAMOND TOOLS WORK
- 6. • The cutting rim or segment of a diamond blade is comprised of metal matrix containing various metal powders and small synthetic diamonds / diamond dust • The diamonds are the abrasive agent responsible for all of the actual cutting / grinding • The metal matrix is designed to wear away at a specific speed • Matrix composition and wear rate is determined by application Synthetic diamond (middle) and various metal powders (left and right) used in the diamond blade manufacturing process BOND DISCUSSION Diamond Bond and Matrix
- 7. • While concrete may be made to a consistent PSI, the aggregate making up that concrete can vary wildly between regions • Due to the variation in aggregate type and hardness, blades may work well in one region yet poorly in another AGGREGATE HARDNESS MAP
- 8. Typical Uses: • Traditional and most popular style of large diameter diamond blade • Available in multiple price points and with both laser and sintered welds • Available in multiple bonds for a variety of applications Advantages: • Excellent cross between cutting speed and blade life • Fits most popular saws in the marketplace Other Considerations : • Difficult to discern difference between high quality and lower quality blades based upon appearance alone • Many technology advances allow increased performance with minimal added cost over this traditional design SEGMENTED BLADES
- 9. TURBO BLADES Typical Uses: • Granite, marble, stone, and decorative applications • Applications requiring a clean, finished cutting edge Advantages: • Rim design achieves a very clean, fine finished edge • Excellent performance in very hard, dense materials such as granite, quartz, and natural stone Other Considerations : • Sacrifices some cutting speed to achieve smoother cut • Larger diameter turbo blades are not widely stocked at traditional construction distribution / supply houses Lackmond Pro Series Hard Materials Turbo Blade Shown
- 10. SEGMENTED TURBO BLADES Typical Uses: • Popular in all general purpose applications • Excellent performance in overlay situations (when undercut segments are present) • Perfect for situations needing excellent cutting speed Advantages: • Combines features of both segmented and turbo style blades • Very fast cutting speed and, usually, excellent blade life Other Considerations : • Often only found in premium level products, so cost can be a factor • Some segment designs are purely for marketing reasons and have no significant or measurable performance impact Lackmond STS5 Demo Blade Shown
- 11. SPECIALTY BLADES Typical Uses: • Wide variety of styles, designs, and materials available to fit any cutting situation • Ductile, Demolition, Steel, and many more applications Advantages: • Specifically designed for niche applications • Excellent performance in stated applications, increasing productivity, worker safety, and lowering costs Other Considerations : • Often only usable for one specific situation or application • Can be expensive depending on product • Less variety of compatible tools than with traditional diamond blades Lackmond 911 Demo Blade Shown
- 12. PATTERNED DIAMOND Typical Uses: • Most popular in stone and granite industries, but also available in higher quality general construction products Advantages: • Patterned diamond blades provide the most efficient arrangement of diamond for extremely fast cutting • Manufacturing processes provide flexibility in designing a bond matrix, making these blades extremely versatile Other Considerations : • Due to labor, manufacturing, and material concerns, these products are generally higher cost and focused on higher end uses Lackmond STS6 Blade Shown
- 13. The term “Undercutting” or “Knife Edging” refers to the premature wear of the weld point between blade segment and core • Usually a result of cutting very abrasive materials • Also seen when cutting THROUGH a slab and in to the sand / gravel substrate Most asphalt / block blades and multi-application blades incorporate undercut protection segments to prevent this issue Undercutting (left) can quickly lead to segment loss (right) UNDERCUTTING / KNIFE EDGING
- 14. UNDERCUT PROTECTION Four separate approaches to undercut protection. • The arrows point directly to the undercut protection segment. • The style used is based upon a number of factors but is most heavily influenced by core design, segment spacing, and manufacturing processes
- 15. Roll tensioning machines like the one shown are used on almost every Lackmond diamond blade The lightly colored “ring” on both sides of the blade core is evidence of pre and post blade tensioning Blade Tensioning is a quality control process performed both prior to & after welding segments to the core • This process ensures that blades run straight and true when at operating speeds • A tensioned blade will cut more straight, more quickly, last longer, and put less wear on the tool • Low cost manufacturers often skip this step and some even paint their blades to hide their lack of blade tensioning BLADE TENSIONING
- 16. GENERAL PURPOSE CUTTING PART 2: TOOLS
- 17. Choke Blade Flange Throttle Lockout Throttle Control Start Throttle Lock Stop Switch Water Tap Starter Handle Illustrations from Husqvarna® K760 product manual Important terms and features for a typical hand held, high speed saw: TOOL OVERVIEW
- 18. Gas Cap Water Valve Blade Guard Starter Handle Adjustable Handle Kill Switch Blade Height Control Wheel TOOL OVERVIEW Important Terms and Features for typical Walk Behind Saw:
- 19. On / Off Switch Handle Air Filter Plunge Release Cutting Channel Sliding Tray Sliding Tray Lock TOOL OVERVIEW Important Terms and Features for typical Masonry Saw:
- 20. GENERAL PURPOSE CUTTING PART 3: HANDS ON
- 21. • Silica Dust Mask (N95) SAFETY BRIEFING: REQUIRED GEAR • Wrap Around Eye Protection • Hearing Protection • Gloves (optional) • Protective Apron (optional)
- 22. Unplug and/or turn off gas tools when changing, inspecting, or mounting a diamond blade Wear safety equipment at all times when operating tools • Cutting and grinding can produce flying debris • Prolonged silica dust inhalation can lead to respiratory issues • In absence of hearing protection, hearing damage can occur with prolonged tool use Keep hands out of cutting areas at all times Cutting and grinding can result in heat build-up • Use caution and tight fitting gloves to prevent accidental burns SAFETY BRIEFING
- 23. Blade mounting instructions • Ensure the blade arrow matches the rotation of the saw. • Most hand held saws have an arrow displayed on the blade guard. • Place the diamond blade on the drive shaft between both flange washers • Lock the shaft • Tighten bolt with supplied wrench until blade is secure • Follow your specific saw’s instructions MOUNTING THE BLADE
- 24. We will be using the Masonry saw for our hands on portion for a number of reasons • Easier to control and feel differences between blade types • Safety • Eliminates user inexperience as a factor in blade performance TURN OFF saw after each cut, BEFORE moving hands to the cutting zone • Allow blade to completely stop before removing material Pay attention to the following factors as you cut: • Attempt to maintain a consistent level of downward pressure on the handle • Feel the difference in cutting speeds across various products and blade types • Listen for sound differences between materials & blade types PROPER CUTTING TECHNIQUE
- 25. Place a General Purpose / Concrete blade on the saw • Make a plunge cut through a piece of non-reinforced concrete • Rotate your sample 90°and begin making a plunge cut crossing rebar reinforcement o Make note of saw feedback, sound, and blade cutting speed o Slightly back off on pressure when hitting reinforcement • Make a plunge cut through a piece of non-reinforced concrete • Make a plunge cut through a piece of granite o Notice how slowly the blade cuts and how the saw head wants to “rise up” as you push the material forward • Make a plunge cut through a piece of lightweight block o Notice how quickly the blade cuts and how little resistance there is to your downward force Discuss differences in blade performance across different materials BONDS: PRACTICAL APPLICATION
- 26. BONDS: PRACTICAL APPLICATION Place a T10 Turbo Blade on the saw • Make a plunge cut through a piece of granite o Notice how quickly the blade cuts compared to the general purpose segmented blade • Make a plunge cut through a piece of lightweight block o Notice how quickly the blade cuts and how little resistance there is to your downward force o Cutting speed should be even greater than that of the General purpose blade o Extended use in this application would lead to excessive wear on the blade; mismatched bond/application Discuss differences in blade performance across different materials
- 27. For handheld saws: • Allow the weight of the tool to apply downward force • Your hands are there only to control the saw Let the blade sink in to the cutting surface prior to pushing forward Begin cutting along your line getting progressively deeper with each pass of the blade • This cutting technique is called Step Cutting and it allows the blade to remove less material each pass • Cutting speed, blade life, and user fatigue are all positively impacted by step-cutting Remove the blade from a cut prior to releasing the saw throttle or turning off power PROPER CUTTING TECHNIQUE
- 28. Move STOP Switch to left position Press in Decompression Valve 1. 3. 5. 6. 4. 2. HAND HELD H/S: STARTING THE SAW Pull CHOKE fully out Press Air Purge 6+ times Depress Throttle Controls & engage Start Throttle Lock Pull throttle cable to start saw
- 29. • NEVER cut in the “Kickback Zone” of a high speed handheld blade • Cutting using the portion of the diamond blade ABOVE the centerline (as shown below) can result in climbing kickback and serious bodily injury • ONLY use the bottom half of a diamond blade when cutting to avoid climbing kickback • Always read and obey all instructions that come with your specific saw NEVER cut with this portion of the blade! SAFETY: KICKBACK ZONE
- 30. Cured Concrete – Non-Reinforced • Depress the throttle / throttle lock and bring the saw to full speed • Staying out of the “kickback zone”, set the cutting edge of the blade on the corner of the concrete surface • Allow the blade to “sink in” to the cut approximately 1”- 2” • Slowly begin moving the saw forward, maintaining control of the saw and allowing the weight of the tool to apply downward force • Keeping the throttle depressed, lift the saw out of the cut • Release the throttle and allow the blade to stop spinning Light Weight Block • Follow the same cutting procedures as outlined previously • Make 1-2 shallow cuts on a piece of light weight block o This process dresses / re-sharpens the blade • Remove the saw from the cut, release throttle, set the saw down once blade has stopped spinning, engage “kill switch” HAND HELD H/S: HANDS ON
- 31. Blade features and how they impact performance Familiarity with commonly used tools • Hand held, high speed saws • Walk behind saws • Masonry Saws Practical Application: Bond Discussion • Why is it so important to match blades to specific applications? Cutting through reinforcement • Hearing sound difference when hitting rebar • Feeling saw feedback change • Proper cutting technique CLOSING DISCUSSION
- 32. THE END THANK YOU! Thank you for completing the Cutting training module. For any questions on this and other products offered by Lackmond Products, Inc. please contact our customer service department at 1-800-850-2044. Also, please see all these products and more on our website: Lackmond.com.