Wet Cutting Vs Dry Cutting Diamond Blades

Despite the fact that there are numerous concrete sawing methods, diamond cutting is among the most widely used and efficient. As diamond blades are less likely to break the surface, they produce clean and fine cuts. They feature artificial diamonds set within the saw blade, which produce additional cutting surfaces as the crystals break. As a result, its efficiency increases with each use. Diamond blades endure longer, resist wear, and provide a superior cut.

Although a diamond blade is used in both sawing techniques, there are several important distinctions between wet and dry cutting. In order to choose the best sawing technique for your needs, it is essential to comprehend how both operate.

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Wet Cutting Vs. Dry Cutting Diamond Blades

There are two methods for cutting with diamond blades: wet cutting and dry cutting. Wet cutting is generally recommended since water and diamonds get along so well. The unspoken rule of thumb says any dry blade can be used wet, but a wet blade cannot be used as a dry blade. A moist blade may occasionally sustain temporary damage from dry cutting.

• Wet cutting: Cleaner cuts, longer blade life, dust control (needs water source).
• Dry cutting: Deeper cuts, portable, safer near electricity, quicker cleanup (creates dust).

Wet cutting is ideal for achieving clean cuts, precision, and safety. In contrast, dry cutting is perfect for achieving deep cuts and is good for small jobs and portability.

Let us understand each cutting method in-depth and know their area of ​​application as well as their advantages and disadvantages.

Wet Cutting Diamond Blades

Wet-cutting diamond blades are designed for cutting in wet conditions or by flowing water as it cuts. The heat produced by the blade's friction with the substance being cut is dissipated by the water. The water acts as a coolant and prevents the tool from overheating. Water also helps in reducing dust and debris produced during the process. This helps in reducing the respiratory health risks. 

Wet cutting blades have high RPM, which results in longer cutting time. To reduce the risk of electrocution, the majority of wet-cutting instruments are powered by gasoline or diesel since they use water. To disperse water while in operation, they may have a hose attachment or a water reservoir.

Wet Cutting Benefits 

The following are some advantages of using wet-cutting concrete:

• More finer cuts: wet cutting can continuously cut for longer periods and also reduces downtime. Wet cutting can produce a cleaner cut without stopping frequently.
• Health and safety: The risk of lung dust exposure is decreased since a continuous flow of water transforms airborne particles into a slurry. There is also less chance of overheating-related risks because the water cools the tool more efficiently.
• Reduced risk of overheating: The machine is less likely to overheat when it is using water cooling. Less heat means more uptime and less maintenance.
• Blade protection: The saw experiences less stress when the surface is kept moist while in use. The water can protect the segments, even though these blades aren't as heat-resistant as dry-cutting blades.

Wet Cutting Drawbacks

Wet cutting may have various serious drawbacks, including:

• Continuous water supply: A steady flow of water is necessary for wet cutting. Locating a dependable water source might be difficult in some building sites. Additionally, as the linked water pump is not intended to be a primary source of pressure, you will need to employ additional equipment to pressurize the water.
• Electrical risks: Any nearby electrically powered equipment may be at risk from the water splashing. Ensure to remove any other tools that will be harmful while using water for cutting blades.
• Possibility of chipping or damage: There is are high possibility of chipping while using wet cutting blades because it can harm some materials, like porcelain, due to its abrasive content. Tile work requires the use of an adjustable blade since it can chip tiles.
• Reduced lifespan: In general, wet-cutting machines are less durable than dry-cutting saws.
• Messier workspace: if water is used on the cutting surface, it may also wet the surrounding area, making the workspace dirty and messy. The process also creates concrete sludge from dust, which needs to be cleaned up, confined, and disposed of properly.

Dry Cutting Diamond Blades

For dry cutting, a specific diamond blade that can tolerate higher temperatures is used. For small-scale construction, it is most frequently used in conjunction with a hand-held saw that has a low horsepower. The saw must free spin between cuts to improve airflow because it relies on ambient air to cool the blade in the absence of water. Concrete dust can be collected in a bag by using a dry-cutting saw in conjunction with a vacuum or dust extractor.

Dry Cutting Benefits

The following are just a few advantages of dry-cutting concrete:

• No water needed: dry cutting blades require no water during the cutting process as they use airflow to reduce overheating. Dry cutting is mainly used in places where there are no water sources.
• Safe near other equipment: Working with Dry cutting blades is much safer. You can use it near electric tools without having a fear of any risks. 
• Sharp details: A dry-cutting saw may produce a smoother, flatter surface and is well-known for detailing and finishing tasks. It can score or produce ornamental patterns.
• Cleaner work site: Wet cutting produces a concrete slurry by combining water and dust. This reduces the amount of dry airborne particles, but it makes cleaning up the mess more difficult. When used in conjunction with a dust extractor or vacuum, dry cutting makes the work site cleaner. A shroud and vacuum cleaner can cut exposure to quartz and respirable dust by 95%, per a Centers for Disease Control and Prevention (CDC) study. 
• Cutting made easier: Dry cutting produces cuts that are straight and shallow. These easy tasks become considerably easier with it.

Dry Cutting Drawbacks

Not all applications are suitable for dry cutting. Some disadvantages of the method are:

• No curved cuts: Only straight lines can be produced by dry cutting. 
• Intermittent use: Dry cutting may require more downtime and take longer to cut. 
• Respiratory risks: The dust emitted during sawing is harmful to one's health if water is not available. A dust vacuum is one example of an engineering measure that might lessen respiratory risks.
• Reduced lifespan: due to the dry-cutting technique, these blades tend to have a reduced lifespan compared to wet-cutting blades. During the cutting process, dry cutting blades generate heat, which results in quick wear and tear of blades.

Wet Cutting vs. Dry Cutting: Which Technique is Best?

The application may determine whether to utilize dry cutting or wet cutting. Both, however, work well for different tasks. For indoor use, dry cutting is usually ideal, particularly in situations where the area needs to remain dry at all times. It is also appropriate for construction locations with restricted water supply. Even If the water flows reduces the amount of dust, wet cutting is still messy.  Nonetheless, thicker materials and tasks requiring continuous rather than sporadic cutting can benefit from wet cutting.

Contractors mostly use wet cutting for masonry, brick, metal, reinforced concrete, and tile work. Because it is less likely to overheat or wear the blade, it can make lengthy, clean cuts. Consider dry cutting as an alternative if electrocution poses a risk. 

Dry cutting is best suited for detailing, shaping, and finishing projects. As long as you take the right measures and let the blade free-spin and cool down occasionally while cutting, you can use dry cutting to make deeper cuts.

CONCLUSION

Knowing the difference between wet-cutting and dry-cutting diamond blades is essential to choosing the right tool for your tasks. Wet cutting can be done for a number of materials as it uses water to cool down. It offers precision and safety by spraying water. On the other hand, dry cooling is ideal for small indoor projects. You can guarantee the optimum performance and intended result for your cutting jobs by choosing the right diamond blade.

Have had a few questions recently about the different types of saw blades so thought it worth a post.
Essentially, there are three main types of diamond saw blades used in the lapidary field – all have their pros and cons.

A) Sintered Blades

Sometimes referred to as Continuous Rim Blades, these blades are more expensive but tend to be longer lasting and offer better performance. Sintered blades are made embedding diamond particles in a metal bond around the rim of the blade – the diamond extends through the full depth of the rim and so as the metal bond rim wears away, new diamond particles are exposed and keep the blade cutting.

These blades are available in premium or economy versions – the manufacturing process is essentially the same but a premium blade will be better quality and should give a cleaner cut.  Please note that even though the sintering process will give a more durable blade, they can easily be damaged by incorrect usage (insufficient cooling, rock jams, etc).

For smaller blades, the sintered metal bond rim will be continuous around the whole rim while for larger blades (say above 16″ diameter), there may be sections cut out along the rim to improve coolant flow and debris removal – these are called Segmented Blades.

The 301 Gemking Blade made by Barranca/MK Diamond is often called a Notched Rim Blade but this is a bit misleading.  This one is still a sintered blade but the deep notches along the sintered metal bond rim allow for better coolant flow. This blade is designed for cutting of harder material but MUST be used with oil – water should not be used with these blades. This blade is just a slightly different type of sintered blade.

As the diamond particles are embedded in a metal rim, over time the surface of the metal bond can glaze over the diamond particles and affect cutting performance.  If you feel that the blade is not cutting as it should, we recommend “dressing” the blade by cutting into it a few times with an abrasive material (ie. dressing stick, old silicon carbide wheel, house brick, etc).  This process re-exposes the diamond particles allowing the blade to cut properly again.

B) Notched Rim

A classic notched rim diamond blade is made by pressing diamond grit into the edge of a solid steel core – the process leaves small notches along the rim where the diamond works to cut the material.  This is a much cheaper process compared to sintering and so these blades are generally much cheaper.  They will not last as long but are very low cost for those on a budget.

For more information, please visit XMF.

They can be made very thin which can be useful for those cutting material where you want minimal wastage.  The notches can be very thin or slightly thicker as shown in the photo above but there will be less diamond to work with compared to a sintered blade so factor this in when considering a blade of this type.

Like the sintered blades, these ones can be dressed if they appear to be slowing down but do this only as needed as these blades are nowhere near as durable as a sintered blade.

C) Electroplated 

Electroplated blades are made by electroplating a thin layer of diamond usually in a nickel metal bond on to the surface of the steel blade. As the diamond is only adhered in a very thin layer onto the surface of the blade rim, these blades are not as durable as a sintered blade.  They are generally quite a bit cheaper than a sintered blade but will not last as long – we do feel that they are better quality than the very cheap pressed Notched Rim blades though.

One advantage is that they can be made very thin so may suit applications where you want minimal wastage of valuable material.  They have also proved popular with our glass customers as a blade that cuts clean with less chipping. Generally not available in very large diameter blades and not suitable for slab saw applications.

These blades should NOT be dressed – this will just wear them out with no benefit. Make sure you are using plenty of coolant – the diamond will rip off in seconds if these blades are used dry or with insufficient coolant.

These are the three most commonly available lapidary saw blades – there are a few other less common types suitable for specialised applications (eg. CBN blades for cutting meteorites or iron-rich material).  Please consider your usage and available budget when selecting a diamond blade.  

The three most important specifications are blade diameter, blade thickness and bore size (ie. centre hole) – please note that these measurements are usually quoted in imperial measurements (inches).  See here for a quick conversion chart for relevant Metric/Imperial measurements.

If we can assist with any advice, please  us via the Contact Page.

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