Metallographic Cutting Machine
The metallographic cutting machine is the cutting equipment used in the preparation of samples during metallographic analysis. Due to the different requirements of metallographic sample preparation, the feeding direction, clamping direction, feeding speed and cooling when cutting samples are required. There are certain requirements for the method, so there are various forms of metallographic cutting machines designed for this preparation process.Metallographic cutting machines are mainly widely used in the interception of metallographic samples, because of their strong adaptability and relatively high cutting accuracy, resin grinding wheels can cut soft metal parts such as copper, aluminum and alloys and hard metal parts such as quenched carbon steel, high speed steel. Diamond cutting discs can cut superhard materials such as cemented carbide, ceramics, etc.
Advantages of Metallographic Cutting Machine
Efficient And Accurate
The Metallographic Cutting Machine can quickly and accurately cut the sample, which can quickly produce a large number of samples and effectively improve the experimental efficiency.
Second, The Operation Is Simple
The Metallographic Cutting Machine adopts a digital control system, which can easily set the cutting parameters of the sample, which has the characteristics of easy operation and low learning cost, which is convenient for the operator to use.
Third, The Cutting Effect Is Good
The Metallographic Cutting Machine has high-precision cutting function, and the cutting quality is stable and reliable in the process of cutting samples, which avoids the problems of uneven cutting and cutting defects that are easy to be caused by traditional manual cutting.
Quality Control And Consistency
Metallographic cutting machines help maintain consistent cutting quality and enable quality control in sample preparation. By providing precise cutting parameters and eliminating operator-dependent variations, they contribute to reliable and reproducible results.
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Experienced team
Our team of engineers and technicians has years of experience in the industry, and we leverage that expertise to provide our clients with the best possible solutions.
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Different Metallographic Slicing Techniques for Metallographic Cutters
Crosscut
1. The sample stage is moved manually or automatically, and the workpiece is fixed on the fixed wheel.
2. The wheels move accordingly.
Hack
The workpiece is firmly fixed on the workbench. The wheel is then guided manually or automatically from top to bottom into the fixed workpiece.
Step Cut X
The workpiece is not cut in one step, but in layers (step by step). This type of cutting is particularly suitable for large, thick workpieces of solid material.
Everything In One Step
The workpiece is not cut in one step, but in layers (step by step). This type of slicing is particularly suitable for large, thick material workpieces where the edges must be clamped (sheets, angles, etc.).
Diagonal Cut
For diagonal slices, the table moves backwards (x-axis) and the wheels move downwards (y-axis). This type of cutting is particularly suitable for asymmetric workpieces or to compensate for the wear of the grinding wheel to obtain a constant depth of cut.
Zigzag Cut
The workpiece is not cut in one step, but in layers (step by step). Zigzag cuts are made in the middle of the workpiece.
Care Tailoring
During manual operation, the clamping table (x-axis) moves forward and backward until the cutting is completed. It starts with a front-to-back motion. Since the contact surface is as small as possible, this type of slicing is particularly suitable for workpieces that require clean edges and material-friendly processing (temperature, deformation).
Rotary Cutting
This process is most commonly used on precision cutting tools. Can also be used for large workpieces with corresponding rotating sample holders. Rotate the sample clockwise or counterclockwise onto the cutting wheel. Quarter or half rotations are also possible. For a round workpiece with a diameter of 50 mm, only a cutting distance of 25 mm is required.
What Are the Differences Between Metallographic Cutting Blade and Ordinary Cutting Blade
Cutting blade thickness
Metallographic cutting sheet than general wet grinding wheel sheet to thin, for example, 300mm diameter alumina general film thickness is 3.2-3.8mm thick, the gold photo is 1.5-2mm thick, thinner is to better control the cutting into the knife cutting stress caused by the plastic deformation of material tissue, but also can better control the accuracy of the cutting position.
Cutting blade elasticity
The elasticity of the gold photo is better than the general-purpose sheet, better elasticity can better buffer the sample tissue plastic deformation brought by the knife load, more flexible to adapt to the metallographic cutting is constantly changing cutting speed to adapt to the changes in cutting torque output.
High efficiency and precision film
Gold photo is also subdivided into high-efficiency film and precision cutting film according to the different cutting precision, the precision cutting film has higher resin content and better elasticity, and the thickness of the cutting film is thinner.
Metallographic Cutting
The process begins by using specialized machinery with specific cutting wheels to separate the material into parts. For larger items such as steel shafts, this stage is important in determining the size of the sample that can be processed analytically. It is worth noting that the choice of cutting wheel depends on the material being processed. For example, alloyed white cast iron may require a cubic boron nitride grinding wheel, while copper may require a silicon carbide grinding wheel.
Metallographic Inlay
After cutting, the sample is mounted to a mounting machine using hot or cold resin. This step is crucial to retain the layered structure of the material. Furthermore, it facilitates the safe handling of samples that may be tiny or sharp during subsequent preparation stages. There are two main mounting techniques: Hot press mounting and cold mounting, and the choice depends on the specific characteristics of the sample.
Grinding And Polishing
After mounting, samples were refined for microscopic examination. In this mechanical preparation, grinding and polishing are performed on specialized machines. In this process, the sample is aimed at a rapidly rotating wheel and the surface is polished or ground, revealing the complex microstructure underneath. The choice of wheel surface depends on its material. Soft materials such as aluminum alloys require a different approach than hard materials such as cast iron.
Metallographic Etching
While many materials are ready after polishing, some require etching to add an extra level of detail. In microscopy, this chemical process enhances the visibility of specific properties, such as grain boundaries or phases. This process can be further enhanced by using additional tools such as specialized filters.
Electrolytic Preparation
Electrolytic preparation offers an alternative to traditional grinding when it may cause sample surface deformation. Using this method, the sample acts as an anode and is placed within an electrolyte suitable for the sample. Surface dissolution occurs under controlled conditions, revealing the microstructure. To obtain detailed microscopic views, further electrolytic etching can be applied to increase microstructural contrast.
Application of Metallographic Cutting Machine
Automotive Sheet Metal
The traditional sheet metal processing procedures are complex, and the cutting accuracy is low, the speed is slow, and the quality is uneven. The laser metallographic cutting machine has a high degree of flexibility, cutting sheet metal accurately and quickly, with good quality, and no tool wear, which improves the utilization of materials and realizes efficient processing.
Chassis Cabinet
Including network cabinets, power cabinets, distribution boxes, etc. The traditional flatbed cutting efficiency is low, and the cutting precision is difficult to guarantee.However , the metallographic cutting machine cant take standardized processing for thin metal sheet, with efficient cutting and short production circle, it can improve the cutting speed and effectively saving the cost of labor and time.
Agricultural Machinery
The traditional manufacture technique of sheet metal parts are complicated and the production efficiency is low. While the metallographic cutting machine is deeply loved by users with a series of characteristics such as high precision, high efficiency and precise cutting. The use of metallographic cutting machine can greatly save mold costs, flexible production, can adapt to various of plates and graphics; high cutting precision, fully meet the high- quality production requirements of agricultural machinery, maximize the utilization rate of plates, and save production costs, time-saving and efficient.
Kitchenware
With people's living standards improved, more and more people are pursuing exquisite and high-quality kitchenware. The traditional cutting method is single, slow cutting speed and low-quality production. While the metallographic cutting machine can realize batch cutting of carbon steel, stainless steel, aluminum alloy and other metals, with fast speed, good quality, high output, and customized production according to user needs.
Fitness Equipment
With the development and popularization of sports concept, the demand of community fitness facilities and gym equipment have gradually increased. To cope with the metal cutting of a large number of tubes and pipes, the using of metallographic cutting machine has greatly improved the production efficiency, so we can easily meet the order needs.
Advertising Industry
It mainly includes metal characters, door heads, various display racks, signs and other products. The metallographic cutting machine has flexible cutting, fast speed, and fine finished products, without the need for secondary grinding. It can perfectly adapt to custom-made fonts of various shapes, with short production cycle, which makes it easier to win the favor of customers and consumers.
Assemble The Torch Correctly
Install the cutting torch accurately and carefully, so that all components are fully matched to ensure the circulation of gas and cooling air. Place all parts on clean flannel to avoid dirt sticking to the parts. Add proper lubricant to the o-ring, subject to the lighting of the o-ring.
Consumables Should Be Replaced In Time Before They Are Completely Damaged.
Do not replace the consumables after they are completely damaged, because the severely worn electrodes, nozzles and vortex rings will cause uncontrollable plasma arcs, which can easily cause serious damage to the cutting torch. Therefore, when the cutting quality is found degraded for the first time, the consumables should be checked in time.
Clean The Connecting Threads Of The Torch
When replacing consumables or performing routine maintenance and inspection, make sure to clean the internal and external threads of the torch. If necessary, clean or repair the connection threads and clean the contact surface between the electrode and the nozzle.
In many cutting torches, the interface between the nozzle and the electrode is charged. If there is dirt on the surfaces of these cutting torches, the cutting torches cannot work normally, and should be cleaned with hydrogen peroxide cleaning agent.
Check The Gas And Cooling Air Flow Every Day
Check the flow and pressure of the gas and cooling air flow before work every day. If you find that the flow is insufficient or there is a gas leak, you should stop the machine immediately to eliminate the inspection failure.
Avoid Damage Caused By Torch Collision
In order to avoid the torch collision damage, appropriate program design should be carried out to prevent the system from overrun walking. The anti-collision device can effectively prevent the torch collision damage.
Operating Procedures of Metallographic Cutting Machine
Connect the power supply, start the motor switch, press the start button, and let the metallographic sample cutting machine idle for a few turns to determine the direction of rotation. If the rotation direction is wrong, it needs to be adjusted.
Clamp the sample, open the movable jaw, put the sample in smoothly, tighten and fix it.
Before cutting, turn on the cooling water, press the water pump button, adjust the cooling liquid device, and cover the protective cover of the cutting machine.
Turn on the lighting button, turn on the lighting settings, and then adjust the screw handwheel at a constant speed, so that the cutting sample gradually approaches the grinding wheel cutting sheet, and the sample is cut smoothly and at a constant speed. When cutting, the coolant must be aimed at the cutting sample, and it must not be too fast, so as not to burn the sample or collapse the cutting wheel of the grinding wheel.
After cutting, clean the cutting machine. cut the power.
What Are the Technical Points of Metallographic Cutting Machine
After each use, cleaning and maintenance work should be done in time, and the deposits in the cutting room and the water tank should be cleaned regularly to ensure the smooth and clean cooling water.
It is strictly forbidden to use cracked or damaged metallographic cutting sheets for cutting work to ensure safety during the cutting process. (It is recommended to use the original cutting blade)
The coolant needs to be replaced regularly to prevent deterioration and failure and affect the cutting effect.
In the future work, each sliding part needs to be injected with lubricating oil frequently.
When replacing a new metallographic cutting blade in the middle, do not tighten the lock nut with too much force to prevent the saw blade from being disassembled or the cutting blade cracking.
If there is an abnormal sound during the cutting process, you should press the emergency stop button immediately and check the equipment. Before repairing or replacing accessories, cut off the power first and wait for the metallographic cutting sheet to stop completely.
If the equipment shakes and other faults, it should be stopped immediately to check and check the direction
(1) Is the cutting blade broken?
(2) Is the cutting speed too fast during the cutting process?
6 Ways to Improve the Speed, Efficiency and Quality of Metallographic Cutting
Eliminate Burrs To Speed Up Your Preparation Process
A burr is a raised edge or small piece of material that remains attached after a specimen has been sectioned. Burrs need to be removed before sample analysis, which adds time-consuming grinding and polishing to your preparation process.
Improve Sample Quality By Avoiding Thermal Damage
Thermal damage is a burning in the material's surface caused by incorrect sectioning. It usually leaves a visible discoloration and changes the micro-structure of the material to a certain depth. Thermal damage has to be removed through a time-consuming grinding and polishing process before analysis.
Improve Reproducibility By Avoiding Cracks In Brittle Materials Or Coatings
Cracking typically occurs in brittle samples or samples with layers, and usually means the sample has to be cut again, adding extra time to your cutting process. This extra time can be avoided by following these simple tips.
Protect Your Cut-off Wheel By Avoiding Pinching
Workpieces of hardened steel tend to build up internal stress during longitudinal cuts. The workpiece will then pinch the cut-off wheel, which can cause it to get stuck or break. At its worst, pinching will deform the workpiece , which stresses the material and means any sample cut from it is no longer representative of the whole – invalidating your analysis.
Learn How To Clamp And Cut Irregular Shapes
An irregular shaped workpiece can be difficult to clamp for sectioning, slowing down your cutting process. If the workpiece is not held well enough, movement during sectioning may mean the sample has to be re-cut.
Don't Cut The Work Surface
Many of us have accidently cut into the cutting table by mistake. How can you minimize the chances of cutting the table?
- Use a lower feed speed
The mechanical impact of a high feed speed can bend the cut-off wheel and cause it to veer off into the table. Choose a slower cutting speed for better stability.
- Switch to a softer cut-off wheel
If your cut-off wheel is too hard for the material, it may deflect off into the table. If you don't want to change your cut-off wheel, you can try a lower rpm.
Precautions for Using a Metallographic Cutting Machine
During the cutting process, if the cutting blade vibrates or makes abnormal noises, be sure to stop cutting.
The workpiece must be clamped stably and firmly when cutting. It is strictly forbidden to perform cutting operations without clamping the workpiece.
It is strictly forbidden to use broken or cracked grinding wheels. When cutting, try to avoid sparks and keep away from flammable and explosive items.
When cutting, the thicker and harder the workpiece, the slower the cutting speed.
After cutting, before the grinding wheel is completely stopped, do not open the protective cover, put your hand in the cutting area to take the sample.
Wear goggles during the cutting process.
Lubricating oil should be injected into each sliding surface frequently during work, and the motor should be maintained according to the motor maintenance method.
The garbage in the cutting machine should be removed in time to ensure the normal circulation of the coolant.
What Are the Emerging Trends in the Global Metallographic Cutting Machine Market
Emerging trends in the global metallographic cutting machine market include the growing adoption of automation and robotics for enhanced precision and efficiency. Furthermore, there is an increasing focus on the development of eco-friendly cutting machines that reduce waste and energy consumption. Another trend is the integration of advanced software and analytics tools to enable real-time monitoring and analysis of cutting processes, facilitating predictive maintenance and improving overall productivity. Additionally, the market is witnessing a rise in the demand for portable and compact cutting machines, catering to the growing need for on-site analysis and testing in industries such as aerospace and automotive.
Our Factroy
Laizhou lailuote testing instrument Co.,ltd. specializes in researching&developing, manufacturing hardness testers and metallographic preparation instruments. Our products are Widely used in quality control, college, laboratories and industries. Founded in 2007, Located in the "base of china hardness testers" -Laizhou city, Lailuote is today one of China's leading manufacturers of hardness testers and metallographic preparation products. Over the years we have built a professional team of engineers, scientists, marketing sales and customer services, in which many people has more than 40 years experience in this field.
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