About Abrasive Cutting
>> What is Abrasive Cutting?
Abrasive cutting is a method of serving ferrous and non-ferrous metals, ceramics etc. with relatively thin abrasive wheel.

An abrasive cut-off wheel is a highly efficient tool holder which functions by presenting to the work, thousands of miniature “cutting tools” Actually, these tiny tools are grains of aluminum oxide or silicon carbide abrasive.

Abrasive cut-off wheels are self-sharpening, because they automatically eject their worn out “tools”. The relative hardness of the wheel bond determines the rate at which the worn “tools” are ejected. Because at very high speeds they are continually sharpened as they cut; abrasive cutting is the fastest cutting method available for many materials.

>> How abrasive cutting reduces your cost.
Abrasive cutting allows dramatic savings in labor costs because it is ten to twenty times faster then conventional metal parting methods. Most metals can be served with the abrasive process at a rate of 3 to 6 seconds per square inch. Quality cuts are produced and pre or post cut operations such as annealing, de-burring and finish grinding are greatly reduced or eliminated. Substantial savings in factory floor-space result because one compactly designed abrasive cut-off machine can do the work of several conventional machines.

>> The right wheel for the job.
In general, maximum wheel life and fastest cutting occur with coarse grit, hard-bond wheels. If burr, discoloration and/or surface hardening is encountered and must be reduced or eliminated, finer grit, softer bond wheels can be used . For tube cutting, fine grit wheels are usually suggested. Fiber glass reinforced wheels are recommended to resist wheel breakage on certain round applications.

>> What about wet abrasive cut-off?
Dry cutting is suitable for most abrasive cut-off applications.

However, some applications, because of production, tolerance or finish requirements, are better suited to the wet abrasive cut-off method, in which coolant is introduced between wheel and work.

UNIMAT’s controlled method of coolant application accurately directs coolant to the point of wheel contact with the materials being cut. This accurate direction and adequate amount of coolant on both sides of the Wheels make the UNIMAT wet abrasive cutting method economical and permit a speedy, efficient operation.

There are four important reasons why UNIMAT abrasive cut off machines Provide the best means for cutting materials.
>> SPEED.
By efficient designing, even the hardest materials can be cut in a matter of seconds.

>> EFFICIENCY.
UNIMAT Abrasive cut off machines are accurate ; they hold length and squareness of the cut within a few thousands per inch of depth of cut. The smooth, burn free cut which is obtained through the wet abrasive method often eliminates the need for machining and grinding operations.

>> AMPLE POWER.
Always use of more efficient wheels results in lower cost per cut. (Provides cooler cutting to assure better quality cuts by maintaining wheel speed under load).

>> SAFETY.
All machines are equipped with wheel guards which completely protect the operator. Besides proper distance and placement of the job also ensure operator safety.

** UNIMAT will run tests.
UNIMAT Engineers will run tests for you and show conclusively which abrasive cutting machine will do the most economical and effective job. These tests will be based on your material, using the latest UNIMAT machine developed to decrease cutting time, reduce abrasive wheel wear and leave a smooth finish.

SALIENT FEATURES.

** Sturdy Construction:
Rugged Cast Iron Body, Rocking Head mounted on Frictionless Bearing with adjustable Stop for limitation of Head movement. Ground Drive Spindle revolving on Frictionless Bearings in Cast Iron dust proof Housing fitted with Grease Stuffer.




** Ensured Safety:
Perfect balancing of the cutting head coupled with additional attachment and counter balancing Buffer unit against sudden shock to ensure safe operation.





** Low Running Cost:
Cost of cutting wheel vis-à-vis wheel life gives an amazingly low running cost factor.






** Superior Surface Finish:
The advance principle of “Cutting off by grinding” offers a smooth glassy surface finish.






** Strike Time Reduction:
The ratio of cutting time to the conventional cutting Process is 30:1.







** Aid To Select Right Unimat Machines:
CHOP STROKE MACHINES are the simplest and are used mostly for cutting bars or tubes in diameters up to 2 or 4 inches respectively and also assorted sections.

OSCILLALTING MACHINES have the advantage over the Chop Stroke of being able to reduce the arc of contact between the wheel and the job. Oscillation is of great advantage when the arc of contact between the wheel and the job would otherwise exceed 2 inches. With ordinary, non-oscillation Chop Stroke machines, excessive heat generates when solids over 2 inches are cut and Coolant cannot reach the cutting edge readily. This results in a serious loss in quality of cut and in the efficiency of cutting.

ROTARY MACHINES permit rotation of both the wheel and job and allows cutting of solids and tubes more than twice the diameter than could be cut by keeping the work piece stationery.




HORIZONTAL MACHINES are used where the length of cut if more. Two types are available:

STATIONARY WHEEL – the job moves against the stationary wheel, usually of smaller capacity, serves for cutting refractories, bricks, tiles, glass and other building materials. STATIONARY JOB the wheel traverses across the stationary job, generally used for cutting plates, bigger size work piece stationary.

How to select the proper abrasive cutting machine?

  • Ask these questions first: What quality of cut do I require? Do I need a wet or dry abrasive cutting machine? Do I need the machine for sample preparation or production purpose? Should I use an automatic or manual machine?

  • Is the machine construction sturdy enough to reduce vibrations, rugged enough to minimize maintenance and give longer life?

  • Are the flanges large enough to provide straight cuts? Are they small enough to maximize the number of cuts per wheel?

  • Does the wheel guard have proper design to let the coolant pass through two sides of the wheel? Does it have a separate coolant chamber built in for proper coolant supply to the cutting zone? Does it have the optimum design for protection and good viewing by the operator of the cutting operation?

  • Is the number of belts provided enough for good wheel drive through spindle? Are the pulley sizes capable of transmitting adequate power from the motor and avoid slippage?

  • Do the electrical equipments used have proper ratings and overload protection?

  • Is the motor big enough to get the job done safely?

  • Is the work holding quick acting? Is it properly designed to hold the job firm enough to take care of any movement during cutting?

  • Does the pump deliver enough coolant for quality cutting?

  • Does the machine cut the quoted size? Is the capacity overstated? Does the rate of cut satisfy my production requirements? Does the machine use proper principle for good sample preparation without even any cracks  & structural changes?

Job Cutting Capacity Chart

Job size

Wheel Diameter

Motor Capacity

Upto 25 mm

Minimum 250 mm

5HP

Upto 40 mm

Minimum 350 mm

15 HP

Upto 100 mm

Minimum 500 mm

30 HP with oscillation

How to select the proper sample polishing machine ?

To select the right spectrometric sample polisher/ grinder compare various on the following parameters:

Ask these questions first:  Are you using the proper equipment vis-à-vis your sample material, type of polish and no. of samples per day?

  • Is the machine construction sturdy enough to reduce vibrations, rugged enough to minimize maintenance and give longer life?

  • Are the discs large enough to provide enough space for polishing?

  • Are the discs mono blocked and heavy enough to provide minimum wobble?

  • Are the discs balanced to give straight polishing surfaces?

  • Is the working area covered enough to give protective support to the sample while polishing?

  • Is the speed of operation normalized to give proper finish and operator ease?

  • Is the suction powerful enough to give proper abrasive paper support to the disc to remove erroneous spectrometric results?

  • Is the suction unit involute for maximum efficiency?

  • Is the suction chamber present for prtection of the fan from dust sparks?

  • Do the electrical equipments used have proper ratings and overload protection?

  • Is the motor big enough to get the job done safely?

  • Is the work holding quick acting? Is it properly designed to hold the job firm enough to take care of any movement during polishing?