a)SimpliMet 1000
Introduction
The SimpliMet 1000 machine is an automatic Mounting Press is a very new and versatile mounting press machine. This machine features electrohydraulic and also dual temperature controls which occur over a wide range of the mounting pressures. These machines are designed to allow for easy and quick preparation of the samples. The SimpliMet 1000 machine also increases the consistency of the specimen over the process of manual pressing.
Aim
The major aim of using the SimpliMet 1000 machine is to easily and quickly prepare consistent samples.
Description of apparatus
The SimpliMet 1000 machine is a very simple machine that comprises of the following apparatus.
Hydraulic jack which is like an automobile jack with a diameter ram of 1.25’’
A timer
A furnace
Electronic controls.
Theory
The use of the SimpliMet 1000 machine is very easy. However, despite its simplicity, the machine has some safety hazards related to its use. Therefore, a number of precautions ought to be taken into consideration while using the machine. To begin with, it is noted that the metallic furnace areas in the Twins of the machine can easily become extremely hot which might burn the user. There is therefore need to prevent the accidental burning, it is important to ensure that the sample prepared together with the Twins provided are given enough time to cool immediately after operation. In addition to this, the temptation of mounting one’s fingers or even the tongue is strongly discouraged.
Experimental procedure
In order to effectively use the machine, it is first of all recommended that the sample specimen to be use be prepared to a specific geometry. Irregular shapes or very large shapes are also discouraged. The samples produced must all easily fit within the particular furnace chamber. The maximum sample size that is required is approximately ½’’ by ½’’ by ½’’. Moreover, it is advisable that the specimen to be evaluated be of a relatively flat side on one side which may be placed down on the machine’s flat hydraulic ram surface. In cases where by the specimens are thick and can easily stand up on the given surface without any external aid, additional preparation is not required. On the other hand if the specimen to be tested is thin to the extent that it cannot support itself on the ram surface, it is advisable to place it in a SamplKlip which has the required surface flush with that of the surface of the ram. The machine is turned on by pressing the provided gray button located on the control console. This is followed by the raising of the ram by the use of the blue arrow buttons so as to place the sample on it. Moreover, it is recommended the samples are positioned on the platform using the sample clips if necessary with the required surface to be examined facing downwards. The ram is then lowered to about 2 inches and the chamber then filled with a completely full scoop of the provided phenolic resin powder. In the case where by two samples are prepared, the divider which is a stainless steel disk is inserted. The first and second step of the procedure is again repeated for the second sample. The lid is then closed by pushing it down and rotating it clockwise to lock. If there exists any difficulties in the opening and closing to lock the lid, the lid is pushed down while rotating and at the same time lowering the sample stage further. The mounting parameters are then set by pressing the white button on the left side. The settings recommended when mounting with phenolic powder are a temperature of 150 degrees, a pressure of 290 bars, a heating time of 1 minute for samples more than 2’’ and a cooling time of at least 3 minutes. The other mounting media might require further consulting of the machine‘s instruction booklet or the professor in charge. The lid is then rotated when the mounting cycle is complete so as to unlock it. It is not obvious that the lid will immediately pop open. If it fails to open, never force it. Instead, the sample stage is simply raised to force the lid to open. The samples are then removed with the help of tongs or by the use of gloves carefully to avoid burns. The machine is then safely turned off.
Results
The finished samples are approximately ½’’ and ¾’’ in height.
b)Grinder Buehler Phoenix 4000
Introduction
The Grinder Buehler Phoenix 4000 is a high speed polisher with high performance and is extremely versatile. The machine is a single platen system applicable for both 10’’ as well as 12’’ platen sections. Moreover, the LCD touch pad of the machine are very durable with easily controllable features such as force, Head speed, Base rpm , the head direction and the platen on/off features. The Grinder Buehler Phoenix 4000 machine features has a simplified user interface whose last settings are retained programmable for grinding as well as polishing parameters. Moreover, the LCD displays the “Polish” and the “Grind” commands which are retained for long and can be easily recalled for future use over and over again. Therefore it means that when an operation sequence is ended by “polish” parameters, the “Grind” button can be pressed to usher in the start without necessarily having to change the initially set parameters. No resetting of the procedure is required in that case. The Grinder Buehler Phoenix 4000 also has the unique Z-axis Macro Material Removal System in its system.
Aim
The main objective of using this machine is to achieve neatly polished and grinded meatal surfaces
Description of apparatus
The Grinder Buehler Phoenix 4000 machine has a number of apparatus as named below.
Splash ring
Cover
Paper holding band
Cloth clamp
1 package containing 2 O- rings
1 package containing samples of polishing cloths and grinding paper
1 box consisting of the polishing wheel
Theory
It is important to note that the polishing tables are usually heavy. Due to this, two methods are mostly recommended especially when lifting the table off its wooden skid. One method is that of lifting on the outside edges of the provided table legs. The second recommended method is an alternate method in which when the table is provided with the lower cabinet, ½’’ thick piece of the plywood is cut to just fit between the table legs which extends past the front of the cabinet module.
Procedure
For normal operation of the Grinder Buehler Phoenix 4000 machine, the power button is pressed on by pressing the ON button. This is followed by running of the controls by also pressing the button RUN. When any of the control buttons is activated, the indicator lamps will definitely light. The rotational speed of the provided platen is then adjusted by either increasing or even decreasing to the point where the desired speed is reflected in the LED indicator. When the water lubrication method is used, the lift and swing dispenser arm is moved to the desired position. The water control button on the control panel is pressed ON so as to start the flow of the water from both the given dispenser arm as well as the bowl flush jet. The water flow of the bowl flush jet is then adjusted with the help of the external water supply valve. Using the control knob located just behind the water dispensing arm, the dispensing arm water flow is adjusted. In the case where the bowl flush is operated only, the water valve is closed by turning the provided knob in the clockwise direction. The Grinder Buehler Phoenix 4000 machine can be used to prepare a number of samples ranging from the cerographic samples, the metallographic samples as well as the petrographic samples. In order to achieve a smooth operation, the polishing wheel is installed by the process of lining up two O – rings or pins on the top of the provided base plate with the holes facing the underside direction of the polishing wheel.
Results
The specimen obtained should be highly reflective and smoothly polished surfaces without any flaws
CSA Saw Struers Accustom-50
Introduction.
The CSA Saw Struers Accustom-50 machine is a high a precision saw cutting machine. The machine has very attractive features that suits for a number of features. The most notable use of the machine is in the grinding of thin sections. In addition to this, the machine can also be used precise serial cutting of all materials ranging from cutting of mineral thick sections to ceramics. Its use for precise and deformation free cutting application is exhibited in the cutting of composites, electronic components, metals, minerals, crystals, sintered carbides, biomaterials i.e. teeth and bones as well as in fiber reinforced materials. The CSA Saw Struers Accustom-50 machine can also be further used in target grinding components.
Aim
The main objective of the use of the CSA Saw Struers Accustom-50 machine is to achieve precision saw cutting of metallic objects.
Description of apparatus
The following are the individual components or apparatus required for the efficient use of the CSA Saw Struers Accustom-50 machine
The cutting wheel mount
Specimen mounting
Parameter control
Position control
Display panel
Position zero
Start/stop buttons
Theory
The CSA Saw Struers Accustom-50 machine has a positioning accuracy of about 5micrometers. The machine can also be pre – set to a constant speed of between 0.005 to 3mm/sec. Moreover, the machine has an adjustable force limit with room for sample oscillation or sample rotation. It also has a highly variable cut – off speed that adds up to about 3000 rpm. In addition to this, the CSA Saw Struers Accustom-50 machine has a database that is responsible for both cutting as well as grinding. This is also coupled with an in built recirculating cooling unit together with some enclosed cutting chamber that has safety switch units. These features enhance the application of the CSA Saw Struers Accustom-50 machine for its highlighted uses.
Procedure for use
The machine is turned on with the power button at the back turned on while ensuring that neither of the specimens or blade is mounted on the machine just before the machine energizes which takes to a minimum of 30 seconds for the CSA Saw Struers Accustom-50 machine to zero. The most suitable blade is then mounted. This is followed by the process of testing the water cooling system just before the cutting process begins. Care is taken to ensure that the external pump is connected to the power bar just behind the table with the ON and OFF control panel of the external pump. The coolant water nozzles are then lined up together with the blades and the pump turned on. The chamber is then checked out to make sure that it is draining freely with the draining tube freely draining into the provided coolant water bucket such that none of the connections between the involved lines leak excessively in the process and that no air is allowed to get into the cut off saw. In addition to this, it is ensured that there exists an acceptable amount of flow as well as pressure which is provided by the external pump. In case there exists insufficient flow, the solution is obtained by following the very same procedure as that of changing or cleaning of the coolant filter. The water is then turned off and the process of setting up the saw continued. The machine is then successfully held in place with the specimen clamped using the provided Allen keys and screws. The positions of the cut are then set up by the use of the x and the y controls which in turn set up the zeros. Care should be taken in this case so as not to use the very fast motion controls especially while positioning the given specimen near the cutting blade. This is because the option does not actually stop once it’s released and may easily lead to damaging of the blade or specimen. The display screen also works to set the cutting distance. It is therefore important to ensure that the total distance that is to be cut is actually less than that particular distance between the beginning of the nut as well as at the edge of the blade. The next step is that of setting up the cutting parameters. This can be done by the use of the saved set of parameters of which it should be ensured that the very same parameters have never been at any point changed since the last time of use. If unsure of the cutting parameters, it is advisable to use slower cutting speeds as this can prevent any possible damages to the machine. The water parameter should always be turned on while the cutting operation is in progress. To start the cutting operation, the external pump is switched on and the green button pressed. It is advisable that you stay with the machine for the whole duration of operation. Otherwise careless mistakes such as those of leaving the saw during the operation process can easily lead to cases of flooding as well as potential electrical shorting of the area around the equipment. Once the cutting operation is set, the cutting time will always be displayed. In case there exists excessive sparks from the cutting process or if the saw motor is heard to be struggling, it is advisable to turn off the saw. When the cutting operation is done, the red stop button is pressed even when the saw is running.
Results
Smoothly cut edges with high degree of precision if the procedure of operation is correctly followed.
