{"id":926,"date":"2019-04-01T12:05:25","date_gmt":"2019-04-01T12:05:25","guid":{"rendered":"http:\/\/foxmet.com\/?page_id=926"},"modified":"2020-01-13T09:15:29","modified_gmt":"2020-01-13T09:15:29","slug":"diamond-aggregates","status":"publish","type":"page","link":"https:\/\/foxmet.com\/index.php\/diamond-aggregates\/","title":{"rendered":"Diamond aggregates"},"content":{"rendered":"\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t
\n

CUTTING VERSATILITY WITH DIAMONDS AGGREGATES<\/h2>\n
 <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t \t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t

Introduction \u2013 Main Targets<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

For last decades and due to a fierce competition, diamond tools\u2019 manufacturing has known lots of improvements.\u00a0 Among them, diamond encapsulation (introduced in the years \u201970) and diamond positioning (introduced in the years 2000 via e.g. ARIX \u2122) have played an important role for cutting performances increases.<\/p>

Diamond tool industry has always been driven by following main challenges:<\/p>

1\u00b0 Increasing tool life<\/p>

2\u00b0 Improving cutting performances<\/p>

3\u00b0 Tool\u2019s versatility (Universal applications)<\/p>

4\u00b0 Productivity and competitiveness increases<\/p>

This is with those targets always present in mind that, in our lecture, we will try to quickly review each of them and to present you a new tooling concept combining 3 cutting modes (chipping, abrasion and shearing off) for achieving those 4 factors.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t

Increased Tool Life<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

As everybody knows it already\u2026..there are 2 main ways for increasing cycle life of diamond tools: either we do reinforce matrices\u2019 wear resistance (e.g. by adding WC\/W2C particles in the bond)\u2026.or\u2026..we do improve diamonds\u2019 retention within metal bonds (e.g. by using Ti clad coated diamonds).<\/p>

Both ways have to be carefully tuned.<\/p>

Indeed, a metal bond showing too high wear resistance may lead to a dramatic reduction of diamonds\u2019 protrusions. This is what we commonly call: \u201cthe Glazing Effect\u201d.<\/p>

On the other hand, if diamond\u2019s retention within metal bonds becomes too strong; risk is high to observe most of diamonds polishing and\/or crushing flat on tools\u2019 working surface.<\/p>

No need to say both phenomena\u2019s are highly detrimental to diamond tools cutting efficiency.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t
\n
\n \n <\/div>\n
\n \n <\/div>\n
\n \n <\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t

Improved Cutting Performances<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

To same extend, diamond tools\u2019 cutting efficiency may be improved by:<\/p>

  1. reducing metal bond wear resistance<\/li>
  2. obtaining higher diamond protrusions through their encapsulation with a layer of hard matrix<\/li>
  3. using coarser diamond grids<\/li><\/ol>

    \u00a0<\/p>

    As mentioned earlier, reducing metal bond wear resistance will automatically affect negatively tool life because of premature crystals\u2019 pull-outs. Remain, thus, the other 2 possibilities for improving tool\u2019s cutting performances.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    Applying encapsulated diamonds in cutting tools manufacturing processes is not an easy task. It requests certain know-how and a good control of the encapsulation process. Indeed, metal layer thickness around each crystal must be well defined and matrix composition close to each crystal (i.e. matrix #1) must be metallurgically\/chemically compatible with main matrix (i.e. matrix #2).<\/p>

    However it is much easier to apply, using coarser diamond grids is more expensive (because of higher coarse grid costs) and risks are higher to get more pull-outs, polished and\/or flat crushed diamonds during cutting cycles. Moreover, it is well known among tool makers that coarse diamond grids are inefficient for cutting hard stones like granite, quartzite, basalt, etc. In few words: there is an actual problem of universality (and\/or versatility).<\/p>

    On the other hand, use of encapsulated diamonds in cutting tools offers an excellent solution to versatility problem. Due to improved diamond retentions as well as to the \u201cdouble protrusion\u201d achieved with wear resistant zones around each crystal, we can create channels onto tools\u2019 working surfaces which not only facilitate debris evacuation but allow also achieving higher cutting rate, at lower machine power.<\/p>

    BUT\u2026\u2026.there is an important danger: the \u201ctyre\u2019s erosion<\/strong><\/span>\u201d.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    Indeed, during cutting operations, both debris\u2019 flow and\/or water stream accelerate in-between diamond crystals (bottleneck effect). This phenomenon digs the main matrix out\u2026\u2026..leading to erosions similar to slightly flat tyres which may originate premature losses of encapsulated diamonds. Hence, tool\u2019s instability will increase and tool life will automatically decrease.<\/p>

    \u00a0<\/p>

    Common ways for tackling this phenomenon consist then in: (1) increasing diamond concentrations, (2) correctly positioning encapsulated diamonds within metal bonds and\/or (3) reinforcing matrices\u2019 wear resistances. Of course, tools competitiveness will be adversely affected as manufacturing process becomes more expensive.<\/p>

    \u00a0<\/p>

    What would be the \u201cideal\u201d solution then?<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t

    The Ideal Solution<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    The “ideal” solution would consist in synthesizing big diamond crystals within which cleavage planes would be perfectly monitored\u2026\u2026..through \u2013for instance- a careful positioning of metal inclusions.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    Unfortunately\u2026\u2026 current diamond synthesis technologies are unable to position metallic inclusions within each crystal and manufacturing big crystals requires long & highly energy consuming synthesis periods.<\/p>

    \u00a0<\/p>

    A real challenge for diamond grids manufacturers!!<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t

    Affordable Solutions<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    Despite above statement, we do believe acceptable solutions however exist. Among them, we would like to highlight 3 of them: (1) diamond clusters, (2) synthesized aggregates and (3) A.C. diamond aggregates.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t
    Diamond Clusters<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t
    Synthesized Aggregates\t<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t
    A.C. Diamond Aggregates<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    As described by G. J. Davies, R. A. Chapman, L. K.Hedges, S. G. Nailer and M. Moore in their paper about \u201cNovel Diamond Structures and Shapes\u201d, diamond clusters are UHP\/UHT crystals synthesized from diamond germs. By an appropriate control of Ultra High Pressure, High Temperature crystallization circumstances and conditions, it is possible to grow germ of diamond particles and clusters of particles dominated by the twinned arrangements allowed by the diamond atomic structure.<\/p>

    \u00a0<\/p>

    Unfortunately, this process is not only very expensive, but also highly energetic. In addition, we experienced most of those clusters were pretty fragile and exploded under impact of hard stones.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    Based on above observations and with the kind collaboration of I.S.M. Ukra\u00efne scientists, we submitted several diamond aggregates under various UHP\/UHT parameters.<\/p>

    \u00a0<\/p>

    We, quite easily, succeeded to create \u201cdiamond-to-diamond\u201d bonds between peripherical diamond grids (e.g. 40\/50 and 50\/70 Mesh) and core\/central ones (e.g. 20\/25 and 25\/35 Mesh). Despite we succeeded to shorter the diamond synthesis cycles, we were constrained by limited UHP\/UHT capsules\u2019 capacities. We also observed original intrinsic diamond properties (i.e. TI and TTI) were quite affected by the process.<\/p>

    \u00a0<\/p>

    Diamond clusters and synthesized diamond aggregates being rather expensive ways of producing resistant diamond agglomerates, we decided to develop and to study alternative products which characteristics would tend to the ones offered by those latest at reasonable costs. Among those potential alternatives, one of them proved, quite rapidly, to be the most promising one: the A.C. diamond aggregates.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t

    A.C. Diamond Aggregates<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    Driven by the willingness of approaching \u201cthe ideal diamond\u201d structure at competitive price, following idea came up to our mind: why not producing a granule containing small and big diamond grids with high wear resistant metal bond and then consolidating such granule?<\/p>

    \u00a0<\/p>

    The A.C. diamond aggregate was born. The principle simply consists in encapsulating both fine peripherical and coarse central (i.e. core) diamonds with a thin layer of hard matrix (matrix #1) and gluing first ones (i.e. peripherical) to latest ones (i.e. core\/central).<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    After a battery of trials on our wear equipment using granite class 5 wheels and after SEM analysis, it occurred that:<\/p>

    • retention of most diamonds was improved (i.e. cleaved grids after insert fractures)<\/li>
    • both diamonds and their aggregates showed perfect distributions<\/li>
    • wide canals, without \u201cflat tyres\u2019 erosion\u201d, were formed due to the double protrusion of each agglomerate and sludge\/debris evacuation were consequently facilitated<\/li>
    • tools\u2019 rate of penetration was increased due to a new cutting mode combining chipping, abrasion and shearing off<\/li>
    • number of polished and\/or flat crushed crystals were drastically reduced on tools\u2019 working surface<\/li>
    • use of low diamond qualities was permissible<\/li>
    • wear resistance of main matrices (i.e. matrix #2) can be substantially reduced\u2026.allowing therefore uses of low cost metal bond<\/li>
    • all above mentioned factors were leading to longer tool life<\/li><\/ul>

      But how does an AC diamond aggregate work?<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t

      Diamond Aggregates - Theory<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t\t\t\t\t

      In conventional diamond tools designed for cutting hard, heterogeneous and abrasive materials like reinforced concrete or like in deep petroleum\/geothermal drilling, it is of common use to mix coarse and fine industrial diamond grits.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t\t\t\t\t

      The main setback of such random mixtures is that finer diamond grits\u2019 comet tails hinder and\/or reduce coarser grits\u2019 protrusion. Finer grits play more the role of fused\/cast tungsten carbides. They harden the main matrix, leading \u2013consequently- to lower cutting efficiency of the tool as cutting mode consists mainly in abrasion.<\/p>

      \u00a0<\/p>

      However\u2026if, at constant diamond\u2019s concentration, finer grits are finely positioned around coarser ones, their respective protrusions will be concentrated in delimitated areas of diamond tools\u2019 inserts\/segments\u2026..forming therefore an aggregate of abrasive particles and showing altogether a higher protrusion.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t\t\t\t\t

      This, in turn, allows easier matrix erosion around and before those delimitated areas\u2026leading to canals formations which, not only, improve sludge\/debris evacuation but, also, allow materials shearing off to take place.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t\t
      \n\t\t\t
      \n\t\t\t\t\t\t
      \n\t\t\t\t
      \n\t\t\t\t\t\t\t\t\t

      Series of tests, conducted at laboratory scale as well as on the fields of operation, have clearly demonstrated improvements of cutting tools performances using diamonds aggregates. Those improvements have been identified by a positive combination of 3 cutting modes:<\/p>

      \u00a0<\/p>

      • Chipping, by the diamonds aggregate as a whole, of soft and abrasive materials (e.g. sandstone, shale, reinforcing bars, etc.)<\/li>
      • Abrasion of hard materials thanks to incorporated fine diamond grits (e.g. flint stones, granite, porphyry, etc.)<\/li>
      • Shearing off of heterogeneous materials due to canals\u2019 presence in-between diamonds\u2019 aggregates.<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t\t
        \n\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t
        \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t\t
        \n\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t
        \n\t\t\t\t\t\t\t\t\t

        This combination, consequently, leads to greater versatility of diamond impregnated cutting tools. For instance, same saw blade can be applied for cutting granite as well as reinforced concrete or marble: an obvious advantage for people working on building sites and under time constraints.<\/p>

        \u00a0<\/p>

        Moreover, further trials showed better cutting performances (i.e. increased rate of penetration and\/or faster cutting speed) achieved at more competitive costs as: both, main matrix composition and diamonds qualities can be substantially reduced.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

        \n\t\t\t\t\t\t
        \n\t\t\t\t\t
        \n\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t
        \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t\t
        \n\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t
        \n\t\t\t\t\t

        Various Types of Aggregates<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t\t
        \n\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t
        \n\t\t\t\t\t\t\t\t\t

        Based on this concept and on our newly developed proprietary technology, it is nowadays possible to produce nearly any kind of diamond aggregates with any types of powders.<\/p>

        \u00a0<\/p>

        Depending on applications (e.g. stone sawing, exploration drilling, etc) and\/or on diamond tools manufacturing processes (e.g. hot pressing, natural sintering, vacuum brazing, infiltration, etc), we are indeed in a position to propose different versions of aggregates to diamond tools manufacturers:<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

        \n\t\t\t\t\t\t
        \n\t\t\t\t\t
        \n\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t
        \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t\t
        \n\t\t\t
        \n\t\t\t\t\t\t
        \n\t\t\t\t
        \n\t\t\t\t\t\t\t\t\t
        1. Encapsulated and pre-sintered Coarse Diamonds surrounded by finer diamonds.<\/li>
        2. Coarse diamonds surrounded by finer ones.<\/li>
        3. Coarse and Fine diamonds surrounded by coarse fused\/cast tungsten carbides.<\/li>
        4. Spherical fused tungsten carbides surrounded by finer diamonds<\/li>
        5. Encapsulated diamonds surrounded by encapsulated finer ones<\/li>
        6. Simple and conventional encapsulated diamonds<\/li>
        7. Others\u2026\u2026.<\/li><\/ol>

          \u00a0<\/p>

          We are not anymore limited to diamonds and\/or to metal powders sizes, shapes and densities.<\/p>

          We may use any kind of spherical, irregular, cast, fine or coarse powders with low densities (e.g. C, Si, SiC, etc) as well as with high densities (e.g. W, W2C, etc).<\/p>

          \u00a0<\/p>

          Our patented process allows today productions of \u2013at least- 10,000 cts per day of aggregates and its capacity may be easily increased. It operates at relatively low temperatures, preserving \u2013 consequently \u2013 all diamonds intrinsic properties.<\/p>

          \u00a0<\/p>

          We are even in position to customize each type of aggregates. Wide ranges of configurations and of compositions are indeed possible.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

          \n\t\t\t\t\t\t
          \n\t\t\t\t\t
          \n\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t
          \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t\t
          \n\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t
          \n\t\t\t\t\t\t\t\t\t

          \u2026\u2026or\u2026\u2026.a combination of each in onions\u2019 like configuration\u2026\u2026<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

          \n\t\t\t\t\t\t
          \n\t\t\t\t\t
          \n\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t
          \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t\t
          \n\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t
          \n\t\t\t\t\t

          Preliminary wear resistance tests<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t\t
          \n\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t
          \n\t\t\t\t\t\t\t\t\t

          Following a modified version of the standard test method for abrasive wear resistance of cemented carbides (ASTM B611-85), each new composition and\/or each new configuration of diamond aggregates were preliminary tested on our laboratory grinding equipment.<\/p>

          \u00a0<\/p>

          Instead of using AISI 1020 annealed steel wheels and Al2O3 abrasives slurry, each sintered insert (containing a new composition and\/or a new configuration of aggregates) was tested onto SiC and onto Granite Class 5 (Balmoral FG) grinding wheels, in dry and in wet conditions, at various peripherical speed carefully monitored by laser and under applied pressures ranging from 1 up to 8 bars.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

          \n\t\t\t\t\t\t
          \n\t\t\t\t\t
          \n\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t
          \n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t\t
          \n\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t
          \n\t\t\t\t\t

          Industrial applications<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t\t
          \n\t\t\t
          \n\t\t\t\t\t\t
          \n\t\t\t\t
          \n\t\t\t\t\t\t\t\t\t

          After having been tested at lab scale, most promising diamond aggregate\u2019s compositions and configurations were selected in order to be tested in situ.<\/p>

          For stone and building applications, several saw blades were field tested under following conditions:<\/p>