What to Do When the Tool Head Blunts? You Need to Understand the Core Logic

2025-10-09

The "blunting" of a diamond tool head refers to the situation where the diamond particles in the tool head lose their sharpness or cutting ability during the cutting or grinding process. This leads to reduced cutting efficiency, severe heat generation, and even the inability to continue cutting.

There are 4 common types of tool head blunting:

The diamond particles become rounded. The sharp edges and corners are worn down, resulting in the loss of cutting sharpness.
The diamond particles are wrapped by the metal matrix. The diamond particles on the surface of the tool head fail to be exposed in a timely manner.
The matrix is too hard. The diamond particles cannot fall off for renewal, and new sharp diamond particles cannot be exposed.
The matrix is too soft. The diamond particles fall off too quickly, leading to low utilization rate, while the surface may still "blunt".

The causes of tool head blunting are as follows:

First, the improper selection of matrix material. Its hardness does not match the material being processed.

Second, the low concentration of diamond. During cutting, the load on individual diamond particles is too high, making them prone to rounding.

Third, poor cooling of the tool head. Excessive heat causes graphitization of diamond or surface damage.

Fourth, unreasonable processing parameters. Deviations in linear speed, feed rate, load, etc., cause the tool head to "slip" instead of "cut".

How to solve the problem of tool head blunting?

First, it is necessary to optimize the matrix formula.

For processing hard materials (such as granite, ceramics), a matrix that not only has a rigid framework support but also can expose the cutting edges quickly should be selected. This ensures that the diamond works effectively and the cutting edges can be continuously exposed.
For processing soft materials (such as limestone, concrete), a harder matrix should be selected to prevent the diamond from falling off prematurely.

Take our iron-Copper-zinc SUZ-06 as an example. As a main powder, this product has a fine matrix structure and good holding force during sintering. At the same time, the processed surface will have a sandy characteristic, which significantly improves the sharpness and prevents the matrix from blunting.

Second, select a reasonable diamond concentration and particle size.

Increase the concentration. This can reduce the load on individual diamond particles and delay rounding.
Choose coarse or medium particle sizes. This helps maintain sharp cutting.

In conclusion, blunting is essentially a phenomenon where "the diamond in the tool head loses its sharpness and cannot renew itself". The solution is to ensure that new sharp diamond particles are continuously exposed, which relies on the control of matrix wear and the design of diamond concentration and particle size.

Please feel free to consult for more details.

Email: export@sagwell.com