Cutting
In a metallographic laboratory, taking the sample by cutting is usually the first step of the ...
Cutting in Metallography – Cut-off Wheels, Coolants, Accessories
Cutting is usually the first step in (stationary) metallographic sample preparation. The right combination of cut-off wheel, machine, and coolant determines cut quality, structural integrity, and the time you save later during grinding and polishing. We supply wheels for steels, hardmetals, ceramics, and non-ferrous materials – including corrosion-inhibiting coolants and hands-on technical advice.
Product Range at a Glance
Abrasive Cut-off Wheels (Wet)
Resin-bonded alumina wheels for universal applications and higher hardness ranges.
- Typical diameters: 250, 300, 350, 400 mm
- Use: Un- and low-alloy steels, cast iron, aluminum, brass, and bronze
- Target: Smooth cut surfaces, low heat input, good service life
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Diamond Cut-off Wheels (Wet cut 200–400 mm)
Precision cut-off wheels with diamond grits for brittle and very hard materials.
- Bond variants tailored to the application
- Use: Ceramics, glass, minerals, hardmetal, or composites
- Target: Dimensional accuracy, minimal affected zone
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CBN Cut-off Wheels
Cubic boron nitride cut-off wheels for iron-based high-strength materials.
- Strength: High cutting performance on ferrous materials, temperature-stable
- Use: High-alloy steels, tool steels, ferrous materials
- Target: Reproducible cuts, minimal temper colors
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Coolants with Corrosion Protection
Fully synthetic, mineral oil-free concentrates, optionally with defoamer.
- Function: Heat removal, chip evacuation, protection of sample surface and machine
- Dosage: Practical; a maximum 5% emulsion has proven effective
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Selection Guide – Material × Wheel Type
Soft/More Ductile Metals (Aluminum, Copper)
- Recommendation: Wet abrasive cut-off wheels (alumina) with suitable bond (Universal up to 40 HRC)
- Parameters: High coolant flow, moderate feed
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Steels up to 40 HRC
- Recommendation: Wet abrasive cut-off wheels (Universal), diameter matched to part geometry
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Highly Hardened Steels (Tool Steels) up to 65 HRC
- Recommendation: Wet abrasive cut-off wheels (“Special”), diameter matched to part geometry
- Notes: Rigid clamping, oscillating cut if required
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Brittle Materials (Ceramics, Glass, Minerals)
- Recommendation: Diamond cut-off wheels; smooth cut, reduced infeed
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Hardmetal (Cemented Carbide)
- Recommendation: Diamond cut-off wheels with suitable bond; consistent cooling
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Hard Coatings or Surface Heat Treatment Zones
- Recommendation: Wet abrasive cut-off wheels “Special”; fine-tune feed, keep cutting heat low
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Process Notes – Ensuring Cut Quality
Clamping
- Single-sided clamping is usually sufficient and helps prevent the wheel from jamming/breaking due to residual stresses being released when stress-bearing fibers are cut
- Use clamping claws or toggle clamps
Cutting Parameters
- Adjust feed and peripheral speed to the material (hardness and ductility), wheel, and diameter.
- General rule for feed: the harder the material, the lower the feed
Cooling
- Ensure sufficient flow rate; direct the jet precisely at the cutting zone.
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Oscillation
- Consider for critical materials to reduce heat peaks and grooves.
Wheel Maintenance
- Visual inspection, timely replacement, ensure the bond suits the application.
Troubleshooting – Typical Issues
Wheel Jams or Breaks
- Causes: Residual stresses in the material, incorrect clamping, excessive feed
- Countermeasures: Clamp on one side, reduce feed, consider a softer bond or a more powerful machine
Temper Colors / Heat Effects
- Causes: Heat buildup, bond too hard, insufficient cooling
- Countermeasures: Increase coolant flow, adjust feed, choose a softer bond
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Rapid Wheel Wear
- Causes: Bond too soft, incorrect wheel type
- Countermeasures: Harder bond, verify material-to-wheel selection
Your Advantages with Schmitz Metallography
- A practice-proven range for metallography – from universal to specialized wheel types
- Expert technical advice – we recommend the optimal wheel for your material and machine
- Fast availability of common diameters
- Fully synthetic, mineral oil-free coolants with corrosion protection
- System approach: cut-off wheel, coolant, accessories – from a single source
Process Integration
FAQ – Cutting
Which cut-off wheel is suitable for general steels?
For most steels, resin-bonded wet abrasive cut-off wheels (Universal) are the first choice. Important are sufficient cooling and a wheel diameter matched to the part geometry. Link: https://metallographie.shop/Cutting
When should I use diamond instead of CBN?
Diamond cut-off wheels are proven for brittle and extremely hard, non-ferrous-based materials (e.g., ceramics, hardmetal). CBN cut-off wheels are the robust option for ferrous, high-alloy steels.
How do I avoid temper colors?
Increase coolant flow, adjust feed, and, if necessary, switch to a softer bond. Our corrosion-inhibiting coolants are designed for metallographic cutting processes.
Why does the wheel jam at the end of the cut?
Often residual stresses in the part are released. Clamp on one side, reduce feed, and use oscillation. If needed, select a wheel with a suitable bond.
What emulsion concentration is appropriate?
A maximum 5% emulsion has proven effective in practice. Details and variants (incl. defoamer) here
Do you support wheel selection?
Yes. We advise on material, bond, diameter, and parameters. Contact: +49 2407 568296-0 | info@schmitz-metallographie.de
