The left image shows the CD-4-15HC diamond cutting blade; The middle and right images show the CRU-10T ultra-thin grinding wheel cutting blade

1、 Sign for temperature regulator samples

The left image shows the application engineer signing for the sample; The right image shows the gasoline engine thermostat and diesel engine thermostat

2、 Sample structure, material, and cutting position requirements

The left image shows the narrowest part of the arc skeleton at 4.7mm; The right figure shows the position where longitudinal cutting is required

1.The outer frame of the thermostat is made of 430 stainless steel

2.The spring is made of 302 stainless steel

3. The rubber hose is made of rubber

4. The gland is made of stamped copper alloy

5. The hardest ones are springs, push rods, brackets, and valve seats, all made of stainless steel

6. Overall, it is a relatively complex composite structure

3、 Cutting plan

Disassemble and cut the gasoline engine thermostat

Due to the presence of springs on the sample, which have pre tightening force, and the inconsistent force between the large and small springs, direct cutting may cause the parts to pop out, making it difficult to find, and there is also a risk of damage to the cutting blade. So first disassemble and then cut.

Post experiment: Different grinding and polishing processes are used for different materials to observe the microstructure and formulate processing technical conditions.

4、 Disassembly of gasoline engine thermostat

4、 Disassembly of gasoline engine thermostat

5、 Selection and use of cutting machines and cutting blades

1. Use METCUT-5 precision cutting machine and CD-4-15HC diamond cutting blade to cut small workpieces such as copper valves and gaskets

There are three reasons:

① The thickness of the CD-4-15HC diamond cutting blade is very thin, only 0.3mm. The use of this cutting blade reduces sample loss, especially for small size samples and samples that require retesting. Various fixtures are suitable for holding small samples, while large samples are not suitable.

② The METCUT-10 manual grinding wheel cutting machine, which is used to cut large-sized workpieces, has a gap of about 3mm between the left and right hand fixtures for vertical straight cutting of grinding wheels. When the sample size is less than 3mm, the fixture cannot hold the sample. Contrary to METCUT-5, large samples can only be clamped using a grinding wheel cutting machine.

The vertical straight cutting of the grinding wheel cutting machine must have a clearance for the lower blade

③ Another important reason for using precision cutting machine METCUT-5 to cut small workpieces and manual grinding wheel cutting machine METCUT-10 to cut large workpieces is to consider how to configure high-performance cutting machines for users in the future. This configuration basically covers the scope of cutting samples in the future. In addition to the feasibility of cutting, the configured model is practical and economical.

That is to say, in addition to temperature regulators, the materials laboratory will also handle the cutting of various samples, and the configuration of this low-speed precision cutting machine and manual grinding wheel cutting machine will be able to handle it freely.

The left image shows using tweezers to install the copper valve into the double saddle fixture; The figure on the right shows the automatic feed cutting with a counterweight of 200g

The left image shows that the cutting surface is very flat; The right figure shows that the cutting loss is indeed small

2. The shell and thermostat body are cut using METCUT-10 grinding wheel cutting machine and CRU-10T ultra-thin grinding wheel cutting blade

The left figure shows that the fixture can easily fix large workpieces with irregular shapes; The figure on the right shows an ammeter assisting in monitoring the magnitude of cutting force

The left figure shows the cutting of the thermostat body, framework, etc; The figure on the right shows the cutting of the protective casing 

For larger components, choose manual grinding wheel cutting machines METCUT-10 and CRU-10T ultra-thin grinding wheel cutting blades for cutting.

The reasons are as follows:

1. The precision cutting machine METCUT-5 has a maximum diameter of 5 inches and a cutting capacity of 30mm. It is specialized in precision cutting of small samples and cannot cover large workpieces. The manual grinding wheel cutting machine METCUT-10 has a cutting blade of 10 inches and a cutting capacity of 90mm, which can cover usage.

2. The size of the thermostat protection shell is large and the structure is irregular, and a 10 inch cutting blade is used to meet the cutting needs of one knife.

3. CRU-10T is an excellent ultra-thin grinding wheel cutting blade, with a maximum thickness of 0.98mm, which is equivalent to the thickness of the diamond cutting blade CD-10-02. However, the cutting speed is faster, and the ultra-thin grinding wheel cutting blade is also cheaper than the diamond cutting blade. For the future configuration of users, the CD-10T ultra-thin grinding wheel cutting blade is naturally selected. The sample has minimal loss after cutting, and the cutting ability, speed, and surface quality are all excellent. 

6、 Conclusion

1. Cutting blade

The CD-4-15HC diamond cutting blade and the CRU-10T ultra-thin grinding wheel cutting blade have both excellently completed the cutting tasks of large and small workpieces, with ideal overall performance and no problems such as damage or vibration. The wear is not significant and the surface is flat.

Especially when CRU-10T ultra-thin grinding wheel cutting blades are used with manual or automatic grinding wheel cutting machines, their thickness is equivalent to that of diamond cutting blades, but the price is much cheaper. They can complete rapid cutting of most materials, and this recommendation has great value. Of course, if some workpieces are not afraid of greater cutting losses, ordinary grinding wheels can also be used to cut blades, with comparable prices.

2. Cutting machine

Considering that users prefer practicality, high cost-effectiveness, and the wide range of applications. So it is paired with precision cutting machine METCUT-5 and manual grinding wheel cutting machine METCUT-10. Selective cutting according to sample size and cutting speed.

If QATM's automatic grinding wheel cutting machine Brillant240 or 250 is used, it can be solved with only one device. It's just that the price is relatively expensive.

3. Cutting method

After verification, the disassembly cutting method can effectively achieve the cutting purpose. Cutting one by one can also bring greater operability and reduce the difficulty of cutting.

 The metallographic cutting plan for the preparation of the above automotive temperature regulator samples is the preparation suggestion given by the application engineers of Kemai Testing (Nanjing) Co., Ltd. through practice. We hope to provide some help to friends. If you encounter any difficulties in the preparation of metallographic samples, please contact Kemai Testing engineers. We are willing to discuss with friends to obtain more convenient methods to prepare more ideal results.