Abrasive Metallographic Cutting Equipment

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Abrasive Metallographic Cutting Equipment
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Abrasive cutting is how the sample leaves the bulk material. A resin-bonded wheel under flood coolant takes the section quickly, and the coolant is what keeps heat out of the structure you are about to examine. NextGen supplies multi-function cut-off saws for steel, alloys and hard materials, for flat, tubular and irregular workpieces.

The machines cut along two axes for larger pieces, hold the workpiece in vices sized for the job, and manage coolant flow so the wheel and the sample both stay cool. Wheels, coolant and clamping come from the same supplier, machines are installed on site, your team is trained on wheel choice and feed rate, and support continues for the life of the saw.

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What Abrasive Sectioning Does

Sectioning is the first step of metallographic preparation, and the cut decides how much of the original structure reaches the microscope. In abrasive cutting a thin bonded wheel runs under flood coolant and takes the section quickly from bulk material or a finished part. Done well, the disturbed layer under the cut is a fraction of a millimeter thick. A wheel that runs hot leaves a deformed or burnt layer that later grinding has to remove, and overheating a steel coupon can mimic a hardened layer that was not in the part. Abrasive cutting suits large parts and a wide range of metals and alloys where productivity matters, while delicate or very hard material may call for a precision cutter.

The Standard Behind the Cut

ASTM E3 is the guide for preparing metallographic specimens. It starts with choosing where to take the section and in which orientation, then cutting it with cooling so the structure is not altered, before mounting, grinding, polishing and optional etching. The guide describes principles rather than a fixed recipe, so the wheel, the feed and the coolant are chosen for the material.

What Affects Cut Quality

Wheel choice follows hardness: hard materials need a softer-bonded wheel that releases dull grains, and softer metals a harder-bonded wheel that does not clog. Coolant flow removes debris and heat, and the clamping has to hold the workpiece rigidly or it moves under the wheel. A steady feed matters, and thick or heat-sensitive parts often cut better with pulse cutting in short intervals or step cutting that removes thin layers. Dull wheels add vibration and microcracks, so worn wheels are replaced.

Abrasive Cut-Off Saws from NextGen

The GenCut GL120XY sections up to 4.72 in (120 mm) and the GenCut GL170XY up to 6.69 in (170 mm). Both have an automated XY table, a 7 in color touch screen with PLC control, quick clamping, two automatic coolant lines and a fully enclosed cutting room. The GL170XY cuts ferrous and non-ferrous metals, heat-treated parts, forgings, semiconductors and crystals, ceramics and rocks, and it adjusts the feed to the hardness of the material. A double hood on the GL120XY keeps the operator clear of the wheel, and the GL170XY opens its cutting room from three sides, up, front and left, so a large workpiece is easy to position. Wheels, coolant and fixtures come from the NextGen consumables range.

For Laboratories

One partner to equip your complete metallography laboratory

Abrasive sectioning is the first step of metallographic preparation. NextGen equips the rest of the laboratory too, from mounting presses, grinders and polishers to hardness, tensile and impact testing, and stays responsible for it after delivery.

  • Equipment, fixtures and software
  • Installation, training, calibration
  • Lifetime technical support

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FAQs

Capacity and size. The GL120XY takes sections up to 4.72 in (120 mm), has a 4 kW input and a 15.75 × 11.81 in table. The GL170XY takes sections up to 6.69 in (170 mm), has a 23.62 × 31.5 in table, a 480 V three-phase supply and the 150 L coolant tank. Choose by the largest section you cut routinely, and check the supply voltage against your shop power. Request a quote.

Both saws cool the cut through two automatic water lines fed from a coolant tank and pump, which keeps the sample from overheating and protects it from burn residue. The GL170XY page recommends avoiding tap water as the cooling liquid, and its rinsing tap is used to clean the cutting room after the work. The GL170XY coolant tank holds 150 L (39.6 gal).

The GL120XY offers flat push cutting and intermittent cutting, with automatic resetting after the cut, and quick clamping to keep the time between cuts short. The GL170XY switches between electronic hand wheel control and automatic control without stopping the cycle, and its touch screen shows the cutting data as the cut runs. Both are controlled from a 7 in color touch screen with a PLC controller.

The product page lists ferrous and non-ferrous metals, heat-treated parts, forgings, semiconductors and crystals, ceramics and rocks, and notes that the list is not closed. The wheel decides the result: soft non-ferrous work, hardened steel, and ceramics or crystals each cut best on a different bond, and the wrong choice shows up as a burnt edge or a glazed wheel. Tell the team what you section most so the wheel can be matched.

Each saw ships with the cutting saw, a coolant chamber, a water tank and pump, a water inlet tube, a drain pipe, wrenches, a cutting wheel and the operation manual. The cut-off wheel and the coolant are consumables, chosen for the material and replaced as they wear. The metallography consumables page lists wheels and cutting fluid for the saws.

When it comes to low speed precision cut off saws for your metallographic needs, NextGen has got you covered. Our GenCut Series - Precision and Abrasive Metallographic Cut Off Machines has all that you need to meet your sample preparation requirements. Whether you need manual precision sectioning equipment or a fully automatic precision sectioning saw, you will be able to find the perfect unit for your quality laboratory needs. Contact us today to learn how we can meet your precision metallographic cutter needs.

The two main factors associated with finding the correct low speed precision saw for delicate metals include the type of material and the hardness value of the material. Our GenCut GL Series - low speed manual and automatic precision cutters for metallographic equipment may be the right solution for you. These units are uniquely designed for delicate cutting processes to ensure no damage to the cut materials.

Absolutely! NextGen offers a full range of consumables for all of your metallographic sample preparation needs. We have consumables covering all precision and abrasive sectioning equipment, metallographic mounting press equipment, and polishing / grinding equipment. You may submit a request for a consumables brochure or a specific set of consumables you require for your metallographic needs.

NextGen has an extensive line-up of metallography cutters. Both precision metallographic cutters and abrasive metallographic cutters of virtually all shapes and sizes are here to meet your technical specifications. Visit our Metallography Cutters section today to learn more and contact our qualified quality consultant to narrow down the cutter that best fits your needs.

As always NextGen's philosophies of ease-of-use, innovation, and robust design are reflected in the metallography precision sectioning equipment manufacturing processes. All of the units come with a user-friendly intuitive interface which allows for ease of operation to engineers of any experience level. The easy-to-read manual combined with advanced cutting functions which come standard in with all of our low speed precision saws make these units desirable for every quality control laboratory. Longevity, time savings, precision and affordability are some of the words that describe our precision metallographic cutter line-up. We invite you to experience the difference for yourself by contacting our qualified technical consultants today.

NextGen Material Testing, Inc. offers a wide variety of low speed precision saws to meet any of your metallography cutting requirements. Our precision metallographic cutter line-up consists of the GL 100 - 2000 Series covering all ranges of material hardness, samples sizes, and precision / accuracy requirements. The precision cutters come with manual and automatic options for the ultimate user experience. Various consumables are available at your request. Contact us today to get the precision sectioning equipment for your metallographic needs!