What is the Advantage and Disadvantage of Diamond Saw Blade

Brazed diamond cutting saw blade is a kind of diamond sawing tool that uses vacuum brazing to fix diamond on the base of the saw blade. At present, it is more and more widely used in sawing engineering. In the future, it is believed that with the gradual development of sawing tools, brazed diamond saw blades will have more development prospects. The main reason is that brazed saw blades have the following seven advantages.

1: The production of vacuum brazed cutting disc is very fast. Although large-scale equipment such as a brazing furnace should be invested in the early stage of vacuum brazing, once the equipment is put into use normally, the whole brazing process is very fast, and the simplification of the production process can reduce the production cost of brazing saw blades, while the standard products of intelligent mechanization will gradually replace the cumbersome ordinary diamond saw blades due to the increase of labor costs and become the mainstream products of industrial cutting in the future.

2: Energy saving and emission reduction. The vacuum brazing cutting blade is used to fix the diamond by brazing in a vacuum environment. Since the whole process is carried out in a vacuum, especially vacuum brazing is a relatively environmentally friendly production method, the whole vacuum brazing process will not generate waste gas and water, it can achieve the green production.

3: The cutting is fast. The diamonds of the vacuum brazed diamond cutting blade are distributed on the surface of the saw blade, all the diamond is exposed, and the  vacuum brazed surface presents an uneven effect due to the brazing process. During the cutting process, the same cutting line speed, the more exposed the diamond, the more cutting edge, the better the cutting effect. In addition, the uneven cutting surface will reduce the area of the saw blade involved in cutting. Under the same force, the cutting strength of the saw blade will naturally increase, so it is obvious that the vacuum brazed saw blade is much faster than the traditional diamond saw blade. Because of this feature, fire rescue will be equipped with this type of saw blade to achieve the purpose of fast cutting.

4: Can be dry cut. Vacuum brazed diamond saw blades are produced by vacuum brazing process. Unlike traditional saw blades, they do not require welding rods or solders for welding, and the temperature of welding rods and solders is relatively low. In order to achieve a good cutting effect , Ordinary saw blades generally need to be cut in a water environment, and brazed diamond saw blades can be used for dry cutting because they are not affected by welding. Of course, in order to avoid the occurrence of excessive diamond carbonization, it is also necessary to ensure that the single dry cutting time should not be too long.

5: The sharpness is extremely high. Brazed diamond saw blades come in a variety of styles, such as serrated saw blades, this particular saw blade can be extremely sharp. Since this kind of saw blade is not suitable for cutting hard materials, it is not widely used at present.

6: Appearance processing is simple and beautiful. Compared with traditional saw blades, vacuum brazed diamond saw blades have the characteristics of beautiful appearance and easy post-processing. Compared with traditional saw blades that require silk screen printing and laser printing, they are much simpler.

7: Wide application. Vacuum brazed saw blades can cut many kinds of hard materials, almost through cutting, which is better than ordinary diamond saw blades, because most ordinary saw blades cannot cut a variety of materials, especially granite saw blades, it cannot be used to cut marble, otherwise there will be a situation where the edge cannot be cut.

Of course, brazed saw blades also have disadvantages, such as the price is relatively expensive, cannot be reused, and the service life of the saw blade is relatively short. However, with the continuous development of brazing technology and diamond technology, it is believed that the price should be continuously optimized, and the service life will be gradually increased, thereby reducing the cost of use and achieving the maximum cutting benefit.

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This article explores the use of diamond blades, from cutting hard building materials to semiconductor manufacturing.

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Diamond saw blades are created by gluing diamond grit towards the blade's steel body, resulting in a harder, more robust blade capable of cutting even the hardest materials.

Diamond Blades and Building Materials 

Diamond is one of the hardest naturally occurring materials known to man. In a diamond blade, the synthetic diamond materials are mixed with other materials such as iron or steel to form the right blade with outstanding diamond segments along the cutting edge.

Diamond blades are generally used for cutting hard materials. Cutting is a fundamental technical procedure in the manufacture of items depending on the technical needs and function of the formed part.

The produced blade is suitable for cutting a wide variety of materials, including concrete, granite, ceramic tile, asphalt, bricks, and other hard stone, as well as nearly any other type of building material.

Advantages of Using Diamond Blades for Building Materials

When applied to suitable materials, diamond blades are extremely sturdy and have an outstanding lifespan. Due to the nature of these blades and the variety of choices to suit the different materials that need to be cut, users can expect blades to last a longer period of time when a suitable blade is picked for a certain material. 

Diamond blades cut swiftly, which expedites the cutting process and reduces noise-related concerns in the workplace. They will not cut in complete silence, but employing a high-quality and material-appropriate diamond blade will significantly reduce the amount of noise generated; reduced resistance equals reduced noise. 

Due to the simplicity with which these blades cut, they generate less heat during operation due to less friction. With the proper blade and the proper usage of a cooling system, little to no heat is generated. The result of these qualities is a comfortable and efficient cutting procedure.

Limitations of Diamond Blades for Building Materials 

The disadvantages of diamond include its low thermal stability, chemical reactivity with iron group elements, and carbonization at 700 to 800 degrees celsius, which normally does not apply to steel production.

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The same is true when cutting nickel-based alloys. Generally, researchers do not advocate using diamond cutting tools made out of high melting temperature metals or alloys. Additionally, diamond tool grinding is time-consuming and costly.

Diamond Blades in Semiconductor Manufacturing

The semiconductor manufacturing method using diamond blades has already improved wafering processes and resulted in significant cost savings in device fabrication. Additional gains in wafer productivity and quality may be made by adopting a systems-based approach to the slicing procedure.

Additional advancements, such as stainless-steel diamond, wheel cores, and increased cutting speeds, have resulted in considerable cost savings for both the materials processor and the device maker.

Today, automated factories with high throughput for workpieces up to 400 mm in blade diameter are available. Previous advancements were concentrated on the slicing machine and cutting wheels, however, slicing involves a plethora of other factors including wheel attachments, crystal mounting for slicing, coolant selection, handling, and worker skill and competency. Controlling all of these factors precisely may result in even more improvements and cost savings throughout the wafering procedure.

Problems of Diamond Blades in Semiconductor Manufacturing

Slicing concerns are becoming more challenging nowadays as bigger and longer crystals are produced. While bigger, longer crystals increase the processor's efficiency, they introduce complications since the current slicing machinery is not built to handle such huge workpieces.

Additionally, larger dimensions result in more waste when rejections occur. With new semiconductor materials costing up to 20 to 30 times the price of silicon and germanium, significant kerf losses and significant reject rates are too costly. The geometry and surface polish of a wafer dictates its quality.

Solutions to Improve Diamond Blades in Semiconductor Manufacturing 

After mounting the blade upon the machine, it is tested for concentricity. Friction and heat may release strains in the core material during operation, allowing tension to relax. As a result, machine tensioning is a frequent procedure.

The diamond wheel head should be dynamically balanced, with clean, parallel, and smooth clamping surfaces. The diamond materials must be carefully chosen for their particle size, strength, and shape. Lastly, the diamond blade must be handled with delicacy. It must be installed, tensioned, polished, and operated appropriately.

All of these elements contribute to the ultimate outcome, which is the efficient and precise slicing of semiconductor wafers to precise tolerances with the least amount of kerf loss and product damage possible.

References and Further Reading 

Dobrescu, T., et al. (). Improving the slicing process characteristic parameters. Proceedings in Manufacturing Systems. https://www.researchgate.net/publication/_IMPROVING_THE_SLICING_PROCESS_CHARACTERISTIC_PARAMETERS

Li, K., et al. (). Analysis of the Dynamic Diameter of Superthin Diamond Blades in the High Speed and Precison Dicing Process. International Journal of Precision Engineering and Manufacturing volume 20 pages–. https://link.springer.com/article/10./s-019--7

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