Do you need to cut porcelain stoneware or ceramic slabs? Have you found the right blade for your workshop?
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When it comes to choosing a blade for cutting ceramics, the choice can be complicated because there are dozens of possibilities depending on the type of ceramic material to be processed, the thickness of the slabs, and the machine used for processing. Each situation requires a specific disc in order to optimize processing times, increase the quality of work and reduce costs.
The ideal ceramic blade must guarante:
of the tile/slab edge (no chipping or cracking)
(in order to reduce production costs)
until the diamond sector is completely exhausted (to avoid constant machine downtime or material wear)
Type of
ceramic materialto be cut: slab (it's important to know the brand) or tile.
Material
thickness: understanding if the ceramic material to be worked on is 3 mm or 3 cm. The thickness to cut significantly changes the type of diamond sector to be used.
: multidisc, tile cutting saw (clipper), bridge saw / banner saw (it is important to define for this type of machine if it has, or not, an inverter for adjusting rpm) and angle grinder/hand grinder.
Type of
final productto be achieved: tiles from big ceramic slabs, skirting, mosaic, kitchen top.
required: to understand the right type of diamond blade.
Following the above list, we can define a list to support the choice of the disc to be used when cutting ceramic tiles, porcelain stoneware, or large ceramic slabs.
Lastra: LAMINAM, NEOLITH, LAPITEC, DEKTON, ATLAS PLAN, INFINITY, RAK CERAMICS, KEDRA, MARAZZI, FLORIM, ULTRA, ABK SLABS, MATERIA, MAXFINE, SAPIENSTONE, ITALSTONE, XTONE, ASCALE BY TAU, LEVEL, STONEGLASS@ '
Tile: glazed or full body
Slab: from 3 to 20 mm (30 mm in rare cases)
Tile: from 6 to 12 mm (20-30 mm for exteriors).
Multiple-blade cutting machines such as FERRARI & CIGARINI, TECNEMA, COSMAC, LEVI TUNISI, PRAGMA made ones.
Tile cutting saws such us the saws made by ADRIATICA, ACHILLI, RAIMONDI, NUOVA MONDIALMEC, BATIPAV, '
Bridge saw machines with an inverter
Bridge saw machines without an inverter
Banner saw: without an inverter
Angle grinder
Multiple-blade cutting machine: strips, slips, skirting, mosaic.
Tile saw: tiles
Bridge/ Banner cutter: flooring, tiles, and kitchen tops
Angle grinders: tiles and manual shaped cut
The finish and cutting speed determine the type of cutting blade to be used. The two factors are always inversely proportional.
Bridge saw with an inverter (adjustable to rpm): high cutting speed
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If you have a bridge saw with an inverter that allows you to adjust the rotation speed of the disc up to rpm, you are in the best position! You can use the new FASTER series blades that allow you to cut all types of ceramics and with a high cutting speed. They are the best for those who want to go fast and do a lot of production.
[The rotation speeds to be set for the Faster blades are: for the 400mm (16' diameter), for the 350mm ( 14' diameter), for the 300mm (12' diameter)]
Bridge saw without an inverter (adjustable up to 2,500 rpm): standard cutting speed
If your bridge saw has an inverter to set the blade rotation speed but it cannot go over rpm (the minimum speed required to be able to use one of the Faster blades) you can use the Poker series blades. The poker blades need a rotation ranging from to depending on the diameter.
In this case, you have to choose the specific blade suitable for the ceramic brand you need to cut and suitable for the type of work to do (straight cut or for the miter cut).
Bridge/Banner saw without an inverter
If you have a bridge saw with no inverter in the main motor of the blade you have a fixed speed, typical in the banner saw machines or in the slightly older machines, then you can use one of the following blades:
Tile saw
For the tile saws (small portable cutters) the blade to be used are those of the LB and KP series. Obviously, these blades are supplied with the appropriate ring spacer (fitting reductions) to be used in the most common cutters on the market (25.5 mm hole ' 22.23 mm hole ' 20mm hole)
Multi-blade cutting machine
For multi-blade machines, the tool selection must include a more specific analysis because the optimal blade can not be known in advance. It depends on a series of factors.
The type of blade is determined case by case according to the number of heads used (multi-blade cutting machines come with 1, 2, or even 3 heads), the thickness of the material to cut and the blade life required.Among the most used blades we can mention: LX39R multi-disc machine blades: among the most used blades, they are suitable for the vast majority of materials and applications (recommended if you do not know which ones to use). LX43R multi-disc machine blades: discs with finer grain segments than the previous ones, ideal for obtaining cleaner cuts.
Angle grinder
For use on an angle grinder, the ceramic cutting disc is the DryCut, a professional disc that can be used dry and that is suitable to cut all types of ceramics.
RELATED BLADES FOR OTHER MATERIALS:
This guide was written in collaboration between Marco Divita, CEO and Founder amastone and Massimiliano Lorandi, Marketing Manager Diatex Spa
Ceramic Porcelain Diamond Blades
A question that gets asked about a number of products is, "Which one should I use?" It is no different when it comes to selecting a ceramic porcelain blade. Many fabricators are constantly looking for the "best" tool. However, the reality is that there is no one porcelain blade that does everything the best. In this article we will take a look at some basic concerns that come with cutting ceramic and porcelain. We will also briefly consider some features of diamond blades that are used for cutting tiles and even porcelain slabs. Along the way we will discuss some of the pros and cons of using specific types of diamond porcelain blades.
If you begin looking for a diamond blade to cut porcelain tiles you will quickly discover that there are many options. Some blades designed for use on tile saws are labeled as 'ceramic blades', others are called 'porcelain tile blades', and others are designated as 'tile blades'. This can make choosing the right blades for cutting ceramic surfaces, porcelain tiles, or other sintered materials a challenge. Why is that the case?
One reason selecting which blade to use can be tricky is that there are a number of design elements present on each blade. For example, there are continuous rim porcelain blades, turbo blades for cutting ceramic materials, and even ultra thin porcelain blades. Additionally, each blade has specific characteristics that distinguish it from its peers. But Why some many different blade styles? The answer comes down to determining what kind of performance measures are important to the one using the blade.
Each professional measures performance a bit differently from others. For example, one installer may focus more on the productivity by keeping a close eye on the speed at which a blade cuts. Another might want a blade that lasts a long time because he or she feels that it is the best option for the budget. Still another professional may want a blade that produces a cut with the least amount of chipping. The visible differences in porcelain diamond blades are elements that address some of these concerns and others as well. Why are porcelain blades visually different from other blades that cut hard materials?
There are many types of stone-like materials used for hard surfaces in the home and in businesses. (We use the term "stone-like" because the word stone is used in a number of ways when talking about various surface materials.) Each material has characteristics that affect its performance in various environments. Some materials are more susceptible to staining, others do not resist heat very well, and still yet there are some stone surfaces that are sensitive to chemicals. Porcelain ceramic surfaces tend to be very resilient when it comes to those factors. However, ceramic materials are very, very hard. This makes it more brittle that other materials because it does not "give" or absorb shock as well as some of the other materials. This means care is needed when working porcelain.
The fact that ceramics are so hard can present issues during the process of cutting. And even though it might not be the hardest material used for flooring, countertops, and wall cladding, it is up there toward the top of the list. So, blade manufacturers have designed diamond blades to meet the particular challenges of cutting porcelain. Let's look at some specific porcelain blades and talk about the benefits of each style briefly.
One of the issues that comes up when working with porcelain or ceramic material is that the material is so hard that it can be easily chipped during the cutting and shaping process. Another factor that can affect the process of working with these materials is the heat that can be generated by the friction of the blade cutting the material. One way blade designers overcome the potential chipping issues is by engineering diamond blades that have a continuous rim. Since the gaps between the segments are very, very small (if the blade has any gaps at all), the blade is in virtually constant contact with the porcelain. This means that once the cut is started, the only area of the porcelain that is being removed is inside the cut itself.
Blades that have segments with gaps tend to knock material off the sheet that is being cut. On the other hand, a blade with a continuous rim or extremely small gaps between the segments, will remove the material through friction and not so much by hitting the edge and ripping the material away. This type of action (the frictional style cutting) means there is less of a risk of chipping the edges of the cut.
Another style of porcelain blade available is the thin rim blade. Since they are so thin, they remove less material at once and therefore they do not chip as easily as other blades do. Also, thin rim diamond blades for cutting porcelain usually have a more pronounced texture on the sides of the rim. This allows for greater material removal, again without beating the edges of the stone. The texturing on the sides of the rim will vary, but they will be designed with diamonds in the bond so that they cut on not only the edge, but also the sides.
Thin rim porcelain blades usually have some method for dissipating heat that is generated by the friction that cuts the porcelain. Everything from air holes in the blade's body to the material of which the blade is made. Air holes allow the blade to "breathe", meaning, the heat that builds up in the metal body of the blade gets released into the air as it escapes via the holes in the blade body. Copper blades also radiate heat away from the rim toward the center of the blade and in this way the rim is cooled.
One of the types of porcelain blades that you will no doubt see is the turbo rim blade. This style of blade is usually designed for fast cutting. They are often times used for cutting hard stone like granite and quartzite. Because they cut hard materials so well, they can also be used for cutting porcelain and ceramic materials as well. While these kinds of diamond blades cut fast, they have a tendency to chip more than other types of ceramic blades when compared head to head. That being said, there are various grades of turbo blades available and not every turbo blade performs at the same level. In fact, some turbo blades are made for cutting ceramic materials.
Turbo mesh diamond blades are designed to be effective for cutting porcelain tiles, panels and even countertops. Ceramic turbo mesh blades bring together the various benefits described above into a blade that is vented, has a thin body, and is textured on the sides of the rim. While this style of blade might not beat other in any one aspect of cutting, it is potentially one of the best all-around ceramic blades if you choose one that is a high quality.
As we have seen, there are many types of blades that can be used to cut ceramic materials, including porcelain. Each style brings some benefits with it. Depending on the person using the blade, the volume of the shop it is used in, and the number of materials that are processed by the shop, the blade chosen might vary. However, which ever blade you need for your situation can easily be found by browsing through our selection of diamond blades.
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