In the previous text, we introduced the cutting plan after disassembling the thermostat of gasoline engine vehicles. This article introduces the practical operation of cutting after embedding the thermostat of diesel engine vehicles.

The left image shows the METCUT-10 manual grinding wheel cutting machine; The right image shows the CRU-10T ultra-thin grinding wheel cutting blade

1、 Key dimensions of the sample

The left image shows the narrowest part of the arc-shaped skeleton, which is about 5mm; The middle picture shows the widest part of the metal shell, which is approximately 64mm; The figure on the right shows a metal part with a height of approximately 66mm

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

2、 Cutting plan

Insert the thermostat of a diesel engine car as a whole and cut it.

Due to the presence of two sets of springs, both large and small, on the sample, with pre tightening force and inconsistent force between the large and small springs, direct cutting will cause the springs to break into scattered semi circular rings, and there is also a risk of damage to the cutting piece by the spring that pops open. So first overall inlay, then overall cutting.

Post experiment: Grind and polish the sample, observe its microstructure, and formulate processing technical conditions.

3、 Insert the thermostat first

The left image shows the use of EpoQuick epoxy resin and curing agent to mix inlay materials; The picture on the right shows the state of the thermostat after being embedded

4、 Selection and use of cutting machines and cutting blades

1. Select METCUT-10 manual grinding wheel cutting machine

There are three reasons:

① The METCUT-10 manual grinding wheel cutting machine can install cutting blades with a diameter of 10 inches and a cutting capacity of 90mm. The embedded thermostat has a diameter of approximately 70mm and a height of nearly 80mm. Choosing a METCUT-10 cutting machine is a perfect match. Small models cannot cut, and even larger models waste cutting blades.

② The unique feature of METCUT-10 is that there is an ammeter on the control panel to assist in monitoring the cutting force and prevent overloading and burning the sample.

③ The T-slot workbench and left and right hand fixtures of METCUT-10 are completely suitable for cutting embedded samples.

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

The picture on the left shows a photo of the thermostat during installation; The picture on the right shows a photo of the embedded thermostat being cut open

2. Select the CRU-10T ultra-thin grinding wheel cutting blade from QMAXIS

The reasons are as follows:

① The overall width, height of the thermostat are 64mm and 66mm, and the size needs to be increased after embedding. The use of a 10 inch cutting blade can meet the cutting needs of a single blade.

② The narrowest arc skeleton of the temperature regulator is about 5mm. To reduce material loss, it is required that the cutting blade be thin. The CRU-10T of QMAXIS (Kemai) 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, naturally select the CD-10T ultra-thin grinding wheel cutting blade.

③ Due to the small sample loss caused by this type of cutting blade, it is particularly suitable for samples that are sensitive to size and require retesting. The cutting loss of the CRU-10T ultra-thin grinding wheel cutting blade is very small, and the cutting ability, speed, and surface quality are all excellent.

5、 Conclusion

1. Cutting machine

The temperature regulator components have diverse materials and structures, high hardness, and larger overall dimensions after being embedded. So choose the powerful METCUT-10 manual grinding wheel cutting machine. Since the thermostat requires ultra-thin cutting blades for cutting and manual loading during cutting, the unique ammeter device of METCUT-10 plays a crucial role& Flash; It can assist in monitoring loading and prevent excessive force from damaging cutting blades and burning samples.

2. Cutting blade

The CRU-10T ultra-thin grinding wheel cutting blade of QMAXIS (Kemai) first solves the problem of 5mm at the narrowest part of the sample, and can also easily handle materials with different hardness. In front of the larger size of the temperature regulator after being embedded as a whole, it can be cut with one knife.

The cutting results show that the material loss is indeed small, which is conducive to retesting dimensions; The cutting surface is flat, reducing polishing time and consumables.

The CRU-10T ultra-thin grinding wheel cutting blade is used in conjunction with manual or automatic grinding wheel cutting machines. Its thickness is equivalent to that of diamond cutting blades, but its price is much cheaper. It can achieve rapid cutting of most materials, and this recommendation has practical value.

3. Embedding method

The size of the thermostat exceeds the commonly used injection cup size, therefore, it is necessary to choose a container with the appropriate size. The EpoQuick cured by QMAXIS (Kemai) for 2 hours fully meets the requirements for inlaying various material workpieces. The various parts of the embedded sample are fixed and will not produce displacement or spring ejection. Research on the structure of the workpiece, retesting dimensions, and observing the microstructure of the sample after grinding and polishing can all be carried out on this basis.

The above is the metallographic cutting plan for the preparation of automotive thermostat samples after inlay, provided by QMAXIS Testing (Nanjing) Ltd. Nanjing Metallographic Laboratory for your reference. Welcome friends who are interested in metallography to discuss the issue of metallographic sample preparation together. You can contact the engineers of pulse detection through WeChat, QQ, phone, and email. Open the official website http://www.qmaxis.cn/ The contact information is located in the upper right corner of the homepage.