Diamond Wire
A diamond wire differs from traditional methods of wire cutting, such as the bandsaw, by using friction from a wire running at speed to grind through material. Why diamond? Because diamond is one of the hardest materials on the planet and is an effective method for cutting through any material that’ s softer than it, which is practically everything. The wire used on an industrial wire saw is typically made from a loop of high tensile steel or synthetic rubber that is connected by a mechanical joiner. On the outside, the cable is impregnated with diamond beads and is coated with an elastomeric compound to help retain the diamond and protect it against corrosion. A wire can consist of one strand or multiple strands braided together to form a single cable.
Advantages of Diamond Wire
Precision and accuracy
Diamond wires allow for exceptional precision, enabling operators to make accurate cuts with minimal deviations. This level of precision is crucial when creating openings for doors and windows or removing specific sections of concrete structures.
Versatility in thickness
Diamond wires can effectively cut through various thicknesses of concrete, ranging from a few inches to several feet. This versatility makes them suitable for projects of varying scales, from minor renovations to large-scale demolitions.
Reduced noise levels
Urban environments or noise-sensitive areas require cutting methods that minimize noise pollution. Diamond wire cutting produces relatively lower noise levels compared to other methods, making it an ideal choice for such environments.
Clean and smooth cuts
The diamond wire creates clean and smooth cuts, reducing the need for additional surface preparation or finishing. This saves time and resources while enhancing overall efficiency.
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Diamond Wire for Granite QuarryFree from damages like beads getting free from the plastic coating, wire breakage, slow cutting orAdd to Inquiry -
Diamond Wire for Marble QuarryMarble quarry wire comes in standard 50 meter length.. Marble quarry cutting wire exceptionallyAdd to Inquiry -
Diamond Wire for Granite Block SquaringThe granite block squaring wire can cut accurately with small inter-space.. Reliable cutting andAdd to Inquiry -
Diamond Wire for Marble Block SquaringCompare to the blade cutting, diamond wire makes lower cutting noise.. Safety, high quarrying, noAdd to Inquiry -
Diamond Wire for Granite ProfilingBy virtue of its greater reliability, wire sawing technology is more and more automated and thusAdd to Inquiry -
Diamond Wire for Marble ProfilingNoise nuisance generated by diamond wire sawing is significantly less than that produced by otherAdd to Inquiry -
Endless Loop Multi Diamond WiresLow powder consuming and less raw material wasting.. Safe and eco-friendly with low noise.. EasyAdd to Inquiry -
Reinforced Concrete Diamond WireWire sawing is a quick, efficient, and economical concrete cutting solution. Wire sawing is theAdd to Inquiry
- Tel: +86-595-22892387
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Why Choose Us
Our product
Diamond segment, diamond tools, diamond blade, diamond fickert, diamond wire, diamond polishing pads, diamond core bits, diamond cup wheels, etc.
Rich experience
We have 20 years experience, JDK has been engaged in manufacturing and exporting worldwide quality diamond tools since 1995.
MR&D
With a professional R&D team of more than 10 people. The development of advanced test equipment for R & D team plays a role as powerful hose in constantly developing new products and maintain technological leadership.
Quality control
JDK build a scrupulous and diligent study of the quality assurance team, not only ensuring the quality of raw materials and finished products, as well as strict monitoring process to ensure product quality at all times under the management of the company strictly.
Diamond wire type K
The diamond wire type K is a nickel-plated core wire with a low concentration of nickel-coated diamonds. The diamonds are extremely firmly bonded to the core wire via a galvanic process. The nickel bonding is resistant to corrosion and has a very high bonding or holding force and thus a long service life. This diamond wire is recommended for machining medium-hard to hard materials. The abrasion of the thin nickel layer on the diamonds can be found after a cut in the cut material of the cutting gap and not in the cut workpiece.
Diamond wire type L
The diamond wire type L is a nickel-plated core wire with a high concentration of nickel-coated diamonds. The diamonds are extremely firmly bonded to the core wire via an electroplating process. The nickel bonding is resistant to corrosion and has a very high bonding or holding force and thus a long service life. This wire is an all-round wire and suitable for medium-hard to soft materials.
Diamond wire type W
The diamond wire type W is a nickel-plated core wire with a high concentration of nickel-bonded but not nickel-coated diamonds. Using a special process, the diamonds are only partially embedded in the nickel layer of the core wire. The nickel bond is resistant to corrosion and has a good bonding or holding force and thus a long service life. This diamond wire is recommended, for example, for cutting plastics.
Diamond wire with pressed in diamonds
Diamond wires with diamonds pressed into a stainless steel wire are offered on the market as the super solution. No corrosion and no material entry of binder - such as nickel - into the workpiece to be cut.
Mining
With the continuous innovation of diamond wire beats production technology, diamond wire mining of granite and other hard stone mines became possible, while the production cost of diamond wire continued to decrease, diamond wire continued to be used in various mines. Large-scale mines will be equipped with diamond wire mining machines in order to complete larger, faster, more tidy, and more planned mining of ore bodies.
Block shaping
Block shaping refers to the use of diamond wires to cut out irregular parts around the blocks, which is convenient for processing in the next process. The most common one is shaping the bottom of the ore body. This can facilitate the cutting of blocks into plates, and the blocks will not appear. Shaking due to uneven bottom, resulting in uneven cutting.
Special-shaped stone cutting
Special-shaped cutting refers to the use of diamond CNC wire saw machines to process the stone to be cut into various shapes such as cylinders, arc plates, and S-shaped objects according to computer programming. Special-shaped stone is mainly used for the cutting of all kinds of irregular stone materials such as text carving, columns, stone carvings.
Sheet cutting
In the field of batch processing of large veneer stone materials, there are currently three methods at home and abroad, including frame saws (sand saws, gang saws), combined circular saws, and multi-rope saws. Compared with traditional sand saws, it has many advantages, such as high efficiency, low energy consumption, high environmental protection, high quality, and operation. Simple and other characteristics, it is a kind of processing method that innovates and replaces the traditional sand saw processing method, and it has a trend of replacing it. Multi-rope sawing machine is a technological revolution in stone slab cutting, and it is a kind of progress across the age.
Steel concrete cutting
Reinforced concrete is a commonly used building material, and it is widely used in houses, bridges, airports and mines. Ordinary reinforced concrete can be divided into 14 grades including C15, C20, C25, C30, C35, C40, C45, C50, C55, C60, C65, C70, C75 and C80. The strength standard of concrete refers to the measured compressive strength of a cube with a side length of 150mm after 28 days of curing. But in the field of reinforced concrete wire saw cutting, we often use the concrete's steel bar content to characterize it, that is, the percentage of the total steel bar area to the sawing area. With the application of concrete, the cutting of concrete has also become a huge project. The commonly used cutting methods now mainly include thermal cutting methods (flame cutting, laser cutting), mechanical cutting methods (high pressure gas crushing, oil pressure crushing), chemical cutting methods (explosive cutting) and diamond tool cutting (especially wire saw).
Steel plate and blast furnace residual iron cutting
When cutting steel plates and blast furnace residual iron, known data show that the cutting performance of diamond electroplated beats wire saws is significantly better than that of diamond sintered beats wire saws. This is because the diamond concentration of electroplated beats is 5 times higher than that of sintered beats. Therefore, the cutting ability of electroplating beats is much higher. Within a short time from the beginning of material processing, the chip space of the sintered beats is filled with material chips. The bond of sintered beats is hard to wear because it is full of material scraps, resulting in the new diamond abrasive grains not being exposed. Eventually, the cutting efficiency is very low or the loss is exhausted, and the cutting cannot be performed normally.
A diamond wire is a cutting device that uses a metal wire embedded with diamond particles as a cutting tool. It is formed by binding a series of metal wires with rubber or plastic material, and the diamond particles are evenly distributed on the metal wires. diamond wires are often used to cut hard materials such as marble, granite, concrete, bricks, and rocks.
The working principle of diamond wire is to grind and cut materials through the hardness and sharpness of diamond particles. When the wire saw passes through the material during the cutting process, the diamond particles will grind and wear the surface of the material to achieve the purpose of cutting. Wire saws can cut by pulling, looping, or reciprocating motions.
It can cut all kinds of hard materials, including stone, concrete, rock and so on. The cutting speed is fast, which can realize efficient cutting operations. The vibration and noise generated during the cutting process are relatively small. The surface after cutting is smooth, reducing the workload of subsequent processing. The cutting width is adjustable, and precise cutting can be carried out according to the needs. diamond wires are widely used in stone processing, construction, demolition, mining and other industries, especially for occasions where large-sized and complex-shaped materials need to be cut.
The cutting principle of diamond wire is to use the hardness and sharpness of diamond particles to grind and cut materials. Diamond is the hardest natural substance known so far and has excellent cutting properties. In a diamond wire, diamond particles are embedded in the metal wire, forming the cutting edge of the cutting tool. When the wire saw is running, the diamond particles touch the surface of the material to be cut, and produce grinding action on the surface of the material through rotation or circular motion. The hardness and sharpness of the diamond particles allow them to grind and abrade the structure of the material to achieve the cutting effect.
During the cutting process, diamond particles will rub and wear against the surface of the material being cut, gradually reducing the volume of the material. Through continuous cutting motion, the diamond wire can cut the material into the desired shape and size along the predetermined cutting path. The cutting principle of the diamond wire is based on the hardness and sharpness of the diamond particles, and the cutting is achieved by grinding and abrading the surface of the material. This cutting method has advantages when dealing with hard materials and large workpieces, and can complete the cutting task efficiently.
Factors Affecting Diamond Wire Cutting Speed and Efficiency
Concrete strength
The strength and composition of the concrete directly influence the cutting speed. Harder concrete will generally require more time for cutting, while softer concrete may be cut more quickly.
Wire thickness and bead/segment type
Thicker wires with larger diamond beads or segments tend to be more durable and provide faster cutting speeds. The choice of wire thickness and bead/segment type depends on the specific project requirements.
Water supply and cooling
Water plays a vital role in diamond wire cutting. It serves to cool down the wire, preventing overheating and helps control dust. Ensuring a sufficient water supply is essential to maintain optimal cutting performance.
There's no end to what diamond wires can accomplish in stone applications. They cut through granite with ease. diamond wire is famous for cutting materials like stone, masonry, reinforced concrete, rebar, and steel embeds. It's one of the most accurate cutting processes available today. Wire sawing is an excellent method to cut through steel pipes; it can assist water utilities a lot. When it comes to cutting through concrete that is exceptionally thick or has a complex form, wire sawing is the best method. It may also be used for neatly cutting flush against existing walls. Wire sawing is a beautiful alternative for specific cutting needs where stitch drilling was previously the only option.
Diamond wire cutting is ideal for sites with restricted access, such as bridge decks or cutting through beams and columns where deeper depth and quicker cutting speed are required. diamond wires offer the most freedom to cut to a greater degree (or 'section' that has to be cut out) because there are few if any, limitations on the depth and size of the cut (or 'section' that needs to be chopped out).
diamond wireing is a versatile and efficient cutting technique that can be used for various applications. It offers many benefits, such as precision cutting, speed, and a lack of mess or environmental impact. When it comes to intricate cuts or tight spaces, diamond wireing is the best option. Jigsaw puzzles are one way to do this when cutting concrete that is particularly thick or of complex shapes. It can also be used to cut neatly with existing walls. For specific cutting needs, jigsaw puzzles are a good choice where previously only needle drills were available.
Diamond wire cutting is ideal for places with restricted access, such as bridge decks, where greater depth and faster cutting speeds are required, or for cutting beams and columns. diamond wires offer the greatest degree of freedom of cutting (or the ‘parts’ that must be cut) because there are few, if any, restrictions on the depth and size of the cut (or the ‘parts’ that need to be cut).
Diamond Wire Cutting Equipment Structures
Diamond wire cutting equipment can be categorized based on its structural design and the type of wire used. Multi wire structure type of equipment uses multiple diamond wires wound on spools. It is typically used for simultaneous cutting of multiple pieces, increasing efficiency and throughput in industrial applications.
Single wire structure category is further divided into two types based on the configuration of the diamond wire:Endless diamond wire type: In this design, the diamond wire forms a continuous, unbroken loop. This type of structure is advantageous for its consistent cutting ability and reduced need for wire changes, leading to higher efficiency and less downtime.
Diamond wire on spool type structure utilizes a single diamond wire wound on a spool. It's a more traditional setup compared to the endless wire type and is used for various cutting applications where the advantages of an endless loop are not critical. Each type of diamond wire cutting equipment has its specific applications and advantages, chosen based on the requirements of the cutting task, such as the material being cut, desired precision, and efficiency needs. The endless diamond wire type, in particular, represents a significant advancement in wire cutting technology, offering enhanced precision and efficiency.
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