Sectioning

Dealing with Slow or Rough Cuts? It Might Be Your Blade.

It’s frustrating when cuts take too long—and even more so when the resulting specimen is rough, requiring extensive grinding. While a consistently sharp blade delivers the best results, constantly replacing blades may signal a deeper issue: the type of blade you’re using.

To troubleshoot sectioning wheel problems, it’s important to understand how abrasive blades function. These blades rely on sharp abrasive particles to cut through specimens. Over time, these particles become dull. There are two primary ways to maintain blade performance:

• Fracturing dull particles to expose new cutting edges

• Ejecting dull particles so that fresh, sharp ones behind them can take over

At first glance, a blade made of easily fractured abrasives and a weak binder might seem ideal. However, each blade contains a limited amount of abrasive material and can only be fractured a finite number of times. Such a blade may perform well initially but wear out quickly—sacrificing longevity for performance.

Blade Selection: A Balance of Performance and Lifespan

Choosing the right blade involves balancing four key factors: speed, ease, quality of the cut, and blade lifespan. These are influenced by several variables:

• Abrasive Material: The size and type of abrasive particles affect cutting speed and quality. For instance, silicon carbide is harder than aluminum oxide but breaks down more quickly, reducing blade life.

• Binder Strength: The binder holds the abrasive in place. A weaker binder allows worn particles to be shed more easily, helping the blade stay sharp but also shortening its life.

• Blade Diameter: Larger blades typically last longer but are more expensive and prone to cutting drift or “wandering.”

• Blade Thickness: Thicker blades are more stable and less likely to break, but they generate more heat and remove more material, which may compromise cut quality.

Most blade manufacturers provide selection guidelines to help users choose the right blade. These recommendations range from general (e.g., “For Cutting Soft-to-Medium-Soft Steels”) to highly specific (e.g., “For Sectioning Hardened Carbon Steels – Hardness Range: 55–65 HRC”).

Start with the Recommendation, Then Fine-Tune

Use the manufacturer’s suggestion as a starting point. If the recommended blade cuts quickly and cleanly but wears out fast, try a blade with a slightly stronger bond—perhaps one meant for a slightly softer material. If this alternative also performs well and lasts longer, test a third blade with an even stronger bond. The goal is to find a blade that achieves the cut quality you need without excessive wear.

Still facing issues with blade selection? Reach out—we’re here to help.