In this article, we will discuss two reasons why ceramic tools can realize significant productivity improvement at the manufacturing site.
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Answer: It is completely different from material used for pottery. There are three main differences.
The main raw material for pottery (plates and bowls) is clay.
Ceramic cutting tools are made from raw materials with high hardness and chemical stability, such as alumina (Al2O3) and zirconia (ZrO2).These are materials that are much "harder" than clay.
Pottery are molded by human hands or with utensils (potter's wheel, etc.).
Ceramic cutting tools are molded by packing the raw materials into a special mold and pressing them with a special device that applies a strong force of about 1 to 2 tons per 1 .
This compresses the material, reducing the gaps between the particles to create a "strong" ceramic tool material.
Pottery is fired at a relatively "low temperature" of about 900-1,300
Ceramic cutting tools are fired at "high temperatures" of 1,500 or higher.
By strictly controlling the baking temperature and time, high-quality and high-performance ceramic tools can be manufactured.
Now it is easy to see the difference between ceramic tools and pottery (ceramic)?
Next, we will discuss the reason why such ceramic tools can cut hard metals such as cast iron, heat-resistant alloys, and hardened materials at high speeds.
What does this mean?
The table on the left represents the tool cutting edge temperature and the hardness of the tool material during cutting.
Metal becomes softer when heated. The same is true of cutting tools. The higher the machining speeds the more the cutting edge temperature increases due to frictional heat with the workpiece in turn reducing the insert hardness. In other words, it becomes softer. At a temperature of 1,000 carbide and cermet hardness drops to about 35% of its hardness when at room temperature.
However, ceramic tools (White ceramic HC1, Black ceramic HC2, Silicon Nitride SX6) have a unique characteristic that results in a smaller decrease in hardness than that of carbide even if the cutting edge temperature rises. In particular, silicon nitride SX6 material maintains 73% of its room temperature hardness, at a machining temperature of 1,000 . High-speed cutting of cast iron and heat-resistant alloys is possible because hardness can be maintained even at the cutting edge temperature range where the carbide becomes soft.
What does this mean?
The table on the left represents the tool cutting edge temperature and breaking strength during cutting. Breaking strength is its resistance to bending. Carbide is strong at room temperature and has the advantage of not cracking easily.
However, for carbide, when the cutting edge temperature rises, the strength decreases, and at a temperature of 1,200 , it decreases to about 35% of its strength at room temperature.
However, silicon nitride SX6 material has a very small strength drop. It maintains about 82% of its room temperature strength, even in the temperature range of 1,200 . Therefore, ceramic tools can machine stably even in the cutting temperature range where the carbide cracks.
We hope this information helped you see why ceramic tools can machine stably even in high-speed areas.
And, that you will discover applications for ceramic tools to help you achieve productivity improvement.
In the world of ceramics, precise and skilled cutting is the hallmark of a true professional. Imagine trying to cut 7/8" thick ceramic with just tile nippers -- a real nightmare for any amateur! It's no secret: using the right tools is crucial.
Here are the key tools and practical tips that will improve your ceramic cutting method.
Hand tools are easy to use and perfect for quick cuts of small to medium-sized tiles. Among these options, the manual tile cutter, tile nippers, and the hack-saw are the most used.
Power tools offer superior force and precision, suited for more ambitious projects or thicker and harder materials. Among these tools, we have the grinder, the electric saw, and the drill-mounted hole saw.
Let's take a closer look at each of these tools.
Ideal for small touch-ups, straight cuts, and cutting tile corners, this is an economical and practical option for any type of project. There are several models of tile nippers, but the most popular remains the parrot-nose.
If you want to cut all types of stone, choose a model with tungsten carbide tips and scoring wheels. You'll be able to cut ceramic thicknesses up to ½ in.
Also called snap cutter, this tool is probably the most used for ceramic laying projects, as it allows for easy straight and diagonal cuts. Their price varies depending on the length of tiles they can cut and the thickness of the tile.
Link to Zmdy Ceramics
Note: Most can cut tiles from ½ in to ? in thickness.
It's your true Swiss Army knife for all ceramic laying projects. Equipped with a diamond blade, this tool is versatile and capable of making various cuts.
Available with or without a water feed system to minimize dust, it is ideal for large jobs and cutting large tiles. There are several types of ceramic saws, but the table top saw with the blade inside or outside remains the most popular option, as it allows for straight, precise, and consistent cuts.
Perfect for round cuts within the tiles, this option is economical and ideal for more technical needs during installation. Most often used for tiling in showers to make holes for shower heads and taps.
Now that you know the most popular tools, let's see together which would be the best tool suited to your needs. Whether you aim for the precision of a straight cut or the complexity of a bevel cut, selecting the right tool is essential to succeed and avoid frustration.
Essential in all ceramic projects, this cut is the most frequent. Here's a selection of the greatest tools.
The bevel cut, or chamfered cut, involves cutting a piece with an angled edge, offering aesthetic finishes. This technique is ideal for shower and wall corners.
Pro tip: to avoid the bevel cut that requires more advanced technique and tools, use a finishing tile angle trim. This can not only simplify installation but also improve the aesthetics of the project. A variety of models is available, including round and square shapes, as well as a diverse colour palette.
This technique allows for creating openings for pipes and electrical outlets. It is commonly used in bathroom and kitchen renovation projects. The round cut inside ceramic or porcelain tiles offers a practical and aesthetic solution to meet the architectural needs of each project.
Opposite to the interior cut, which focuses on centred cuts like those made with a hole saw, the notch cut refers to cuts made on the outer edge of the tiles. This method is often used to create circular shapes or specific angles.
The thickness of the ceramic tile is a determining factor in choosing the cutting tool. For tiles up to a half-inch, a manual tile cutter or ceramic pliers suffices.
For thicker or more resistant materials, favour power tools like the grinder or a saw with a larger diameter blade.
Mastering the techniques and tools for ceramic cutting is a pillar for successful renovation projects. Remember to plan for a percentage of loss when cutting your tiles. For straight laying, it's advisable to add 5% for loss, while for diagonal laying, plan between 10% and 15%.
To learn more about the big world of ceramics, we invite you to consult our other articles on the subject: learn more about the best floor coverings for underfloor heating in Quebec and find out if installing new ceramic on an existing floor is possible.
Are you interested in learning more about uses for ceramics? Contact us today to secure an expert consultation!