Welding of segments and saw blades

On this page you will find technical information and sample calculations.

1. General Information
The following saw blade / diamond segment combinations can be welded using a modified Nimak Power-KES 20000 welding machine and additional tools

Saw Blade diameter	120 - 1600mm
Saw Blade material thickness	1,2 - 3,5mm
Saw Blade material	75Cr1, 80CrV2, 25 ChroMo 4
Segment material	Cobalt or bronzemixtures,  completely interspersed with diamondgrains
Segment height	8, 10, 11, 17mm
Segment thickness	2,4 - 4,5mm

2. Welding process
This data is based on manual handling. If a tool for automatic handling is attached to the machine the total welding
time decreases accordingly.

Insertion of segment into electrode Incl. turning of saw blade	1,5s
Clamping segment and saw blade	1,0s
Relieving segment feed	1,0s
Closing, welding, opening	2,0s
Opening clamp	1,0s
Total welding time for 1 segment	6,5s

3. Calculation example for annual production of saw blades (diameter 190mm 12 segments)

Total welding time of 12 segments	78s
Saw blade changing time	15s
Total welding time of 1 saw blade	93s
Shifts per day	2
Worktime per shift	7,5h
Avg. availability	90%
Quantity per day	523
Workdays	220
Quantity per year	115.000