Are More Segments Always Better? Understanding Diamond Tool Design

The number of segments on a metal diamond grinding disc or polishing pad is one of the first things professionals look for when choosing diamond tools for surface preparation or polishing. Although it may appear obvious at first that more segments equate to better performance, the truth is more complex.  How the tool interacts with the surface is greatly influenced by the number of segments, and the best option will vary depending on a number of variables, such as the type of machine, the desired finish, and the hardness of the concrete.

A metal bond diamond grinding tool with more segments typically has a smoother finish. The reason for this is that more grinding edges distribute the load, which lessens the strain on each segment and permits finer surface contact. This can be ideal for medium to light grinding applications or for achieving a clean finish before polishing. However, this also means slower material removal rates, which can be a disadvantage when tackling aggressive grinding tasks.

Conversely, fewer segments make the tool more aggressive by concentrating the grinding force into fewer points. When working with exceptionally hard surfaces or removing heavy stock, this configuration is advantageous. For instance, trapezoid magnetic PCD tools are made with fewer but more powerful segments to remove glues, epoxy, and thick coatings as effectively as possible.

It’s also vital to balance the segment count to the grinder’s power and the operating surface area. While smaller grinders may benefit from fewer segments to retain performance, larger machines can accommodate tools with more segments. Furthermore, results are also influenced by variables including grit size, bond type, and segment geometry. For instance, concrete diamond cup wheels with medium segment count and turbo-style layout can strike a good balance between speed and surface refinement.

In summary, it's not always advantageous to have more divisions. Rather, selecting the appropriate configuration for the task yields the best results.  When selecting segment counts, surface prep experts must take into account the desired polish, coating thickness, and state of the floor.