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Please  read  this instruction  manual  carefully  and  follow  all installation,  operating  and  safety  guidelines. 

42 

PICO-155S Precision Saw

 

I

NSTRUCTION 

M

ANUAL 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  ▲ 

3601 E. 34th St. Tucson, AZ  85713  USA  Tel. +1 520-882-6598  Fax +1 520-882-6599  email: [email protected]    Web: http://www.metallographic.com 

 

 

 

 

9.0  Precision Wafer Sectioning

 

 
 

 

9.1a   PRECISION WAFER SECTIONING

 

 

Precision wafer cutting is used for sectioning very delicate samples or for sectioning a sample 
to a very precise location.  Precision wafering saws typically have micrometers for precise 
alignment and positioning of the sample and have variable loading and cutting speed control 
(see Figure 9-1).

 

 

 

 
 

 
 
 

 
 
 

 
 
 

 
 
 
 

Figure 9-1 

PICO-155S Precision wafering saw 

 

9.1b WAFERING BLADE CHARACTERISTICS

 

 

In order to minimize cutting damage, precision wafer cutting most frequently uses diamond 
wafering blades, however for some materials the use of cubic boron nitride (CBN) is more 
efficient. In addition, optimal wafer cutting is accomplished by maximizing the abrasive 
concentration and abrasive size, as well as choosing the most appropriate cutting speed and 
load. Table III provides some general guidelines and parameters for precision sectioning a 
variety of materials. 

 

The particle size of fine diamond grit blades is 10-20 microns or approximately 600 grit.  For 
medium grit diamond wafering blades, the particle size is 60-70 micron or 220 grit.  For these 
types of wafering blades, the abrasive is mixed with a metal binder and then pressed under 
high pressure (Figure 9-2).  As will be discussed in the next section, periodic dressing / 
conditioning of the metal pressed blades is required for optimum cutting performance of the 
blade. 

Содержание PICO 155S

Страница 1: ...raphic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Equipment Type Precision Wafering Saw for 6 inch blades will accept 3 4 5 and 7 inch blades Model PICO 155S Precision Saw Electrical Requirements 110 220 Volts single phase Frequency 50 60 Hz Motor Horsepower 150 watts Manual Revision Date January 2020 ...

Страница 2: ...rm to such description THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE THIS WARRANTY STATES PACE TECHNOLOGIES ENTIRE AND EXCLUSIVE LIABILITY AND BUYER S EXCLUSIVE REMEDY FOR ANY CLAIM FOR DAMAGES IN CONNECTIONS WITH PACE TECHNOLOGIES PRODUCTS PACE TECHNOLOGIES WILL IN NO EVENT BE LI...

Страница 3: ...etween Buyer and Seller Buyer s rights under the warranty shall be suspended during any period of such default and the original warranty period will not be extended beyond its original expiration date despite such suspension of warranty rights 7 MISCELLANEOUS PROVISIONS This agreement has been made in and shall be governed by the laws of the State of Arizona These terms and conditions and the desc...

Страница 4: ...phic com Please read this instruction manual carefully and follow all installation operating and safety guidelines iii Contents Page Warranty i 1 0 Product Description 1 2 0 Shipping Unpacking and Installation 5 3 0 Safety Guidelines 12 4 0 Start Up and Operation 14 5 0 Maintenance 21 6 0 Trouble Shooting 23 7 0 List of Spare Parts 24 8 0 Precision Wafer Sectioning 42 ...

Страница 5: ...etallographic laboratory The PICO 155S has the ability to cut at speeds ranging from 50 to 1500 rpm with loads ranging from 0 up to 1000 grams The PICO 155S is very robust and durable precision saw with its cast aluminum alloy and stainless steel construction The PICO 155S utilizes diamond wafering blades ranging from 3 to 7 inches in diameter A new feature and benefit of the PICO 155S is that it ...

Страница 6: ...monized Standards EN ISO 1200 2010 EN 61010 1 2010 EN 61326 1 2006 1 2 Technical Specifications Electrical specifications 110V 220V single phase Motor power 150 W 24V 50 60 Hz Cut off wheels 3 7 inch diameter blades Wheel arbor 0 5 inch 12 5 mm diameter Speed 50 1500 rpm Load 0 1500 grams Weight Approx 65 lbs 30 kg Dimensions WxDxH Hood closed 14 5 x 18 x 14 5 368 mm x 457 mm x 368 mm Hood open 14...

Страница 7: ...PICO 155S Precision Saw INSTRUCTION MANUAL 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com NOTE Assembling the counter weight rod will add 4 75 120mm in depth 14 5in 368mm 18 0in 457mm 14 5in 468mm 23 0in 584mm 19 0in 483mm ...

Страница 8: ... feedback The PICO 155S is equipped with a 150 W motor that has a feedback loop for maintaining the cutting velocity even under higher loads and increased drag In addition the circuit board has an overload protection feedback which will stop the motor if the blade becomes jammed or pulls too many amps Easy to use The PICO 155S is an easy to use precision cutter with simple controls Simply align th...

Страница 9: ...ping and Installation 2 1 Unpacking Unit is delivered in a box Unpack and check for completeness of parts Crate Measures WxHxD 24 x 36 x 23 Crate Weight Approximately 105 lbs 2 3 Installation Take care to avoid bodily injury Install unit carefully Improper installation voids warranty The PICO 155S should be placed on a flat stable surface Connect the micrometer by pushing the micrometer flush then...

Страница 10: ...m 2 3 1 Installation Coolant Tank 1 Insert Stainless Steel Tank cover tray onto coolant tank with the larger diameter hole located on the back right side of the tank Slide tank into chamber 2 Slide in the left side of the two piece stainless steel sample tray cover and then the right side cover 3 Clean and insert pump filter through both the sample tray cover and the stainless steel tank cover Ins...

Страница 11: ...DO NOT tighten bolts on sample support arm at this point 3 Push micrometer into the outer shaft guide thus pushing the micrometer shaft into the machine While holding micrometer in place tighten set screw on outer shaft guide NOTE The hole in the micrometer does not need to line up with the bolt and DO NOT over tighten the bolt as this may damage and pinch the micrometer 4 Attached sample fixture ...

Страница 12: ... 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com 2 3 3 Installation Weight and Counter Balance 1 Attach load arm Then snugly tighten 2 Attach counter balance rod 3 Attach sliding counter balance weight 4 Attach main sliding weight 5 Attached additional loading weights if desired ...

Страница 13: ...com Web http www metallographic com 2 3 4 Installation flanges and blade Arbor size is 1 2 inch diameter Use largest flange as possible for more blade support Follow recommended guidelines for blade choice Attach outside flange Attach end cap and bolt Note It is recommended that the blade be dressed periodically to optimize its effectiveness Tighten bolt to secure wafering blade Adjust mechanical ...

Страница 14: ... Even for hard ceramics materials dressing is important as the wafering blades are metal pressed blades and the metal from the blade itself can coat or blind the diamond thus resulting in less efficient cutting Proper dressing should be conducted at slow speeds and low loads e g 300 rpm and low feed rate The Dressing button should be used to set the machine to the proper rpm Align dressing fixture...

Страница 15: ...t is recommended that the sample be positioned on the back side of the blade This will reduce the tendency of the sample to jam the blade Machine can run at either 110V or 220V power Connect the electrical plug and activate the on main power switch note the hood must be closed for power to turn on at the front panel Verify that the emergency stop switch is deactivated and the system will be ready ...

Страница 16: ... well as improper operation voids all warranty claims All service issues need to be reported to the manufacturer supplier Before operating cutting chamber hood must be closed Use only certified wafering wheels from a professional supplier Improper blade selection voids warranty For appropriate blade selection refer to the Abrasive Blade Selection Guidelines Chart in Section 9 Disconnect power befo...

Страница 17: ...op Corrective measure If cut off wheel does not power down disconnect power supply cord and call service technician Safety cut off Switch 3 4 Safety Tests Examine and verify that the PICO 155S wafering saw safety devices and operating performance are in good working condition prior to use The following safety checks are considered important Emergency stop switch Emergency stop switch Test Activate...

Страница 18: ... RPM Adjustment Slider Press and hold to move the slider left and right This slider adjusts RPM rapidly The slider location is proportional to the RPM range of the PICO 155S Leftmost location is 0 RPM rightmost location is 1500 RPM 4 Start Stop Press to start and stop the machine 5 Programmable RPM Preselects Press one of the three buttons to change the RPM to the displayed number Press and hold t...

Страница 19: ...locking bolt To prevent shaft from turning use wrench to hold in place Changing Blade Remove Loosen by turning counter clockwise Tighten Turn clockwise 4 4a Zeroing the micrometer 1 Turn micrometer on with left button 2 Press left button again and hold for several seconds until set starts to blink in the upper right hand corner of the screen 3 Press the right button several times until the numbers...

Страница 20: ...f the specimen during cutting 2 For soft gummy materials it is recommended that the sample be positioned towards the back side of the wafering blade For this condition the blade is rotating up into the specimen note if the blade is positioned to the front the blade tends to grab the sample and pull it down into the blade thus jamming and tripping the safety overload protection for the motor 3 A co...

Страница 21: ...nch Diamond Blades 1 2 Arbor 0 012 thick Pace Product Name Catalog Number Packaging per box 4 fine grit low concentration wafering blade WB 0040LC each 4 medium grit low concentration wafering blade WB 0045LC each 4 medium grit high concentration wafering blade WB 0045HC each 5 inch Diamond Blades 1 2 Arbor 0 015 thick Pace Product Name Catalog Number Packaging per box 5 fine grit low concentratio...

Страница 22: ...nd wafering blade WB 0060EPD each CBN Wafering Blades 1 2 Arbor Pace Product Name Catalog Number Packaging per box 4 CBN wafering blade WCBN 0045 each 5 CBN wafering blade WCBN 0055 each 6 CBN wafering blade WCBN 0065 each 7 inch Abrasive Blades 1 2 Arbor Pace Product Name Catalog Number Packaging per box 7 abrasive blade alumina general purpose MAX 7000S 10 pkg Miscellaneous Pace Product Name Cat...

Страница 23: ...Start cut 5 Remove and clean specimen after cutting 4 8 1 Sample Fixturing For proper clamping use the appropriate clamping vises to securely hold the sample in place It is recommended that both sides of the part be clamped to avoid pinching of the blade possibly breaking the blade and to minimize burning of the work piece during cutting For proper fixturing take into account the initial stress of...

Страница 24: ...AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com 4 8 2 Included Sample Fixtures Universal Vice Tear Drop Vice Large Universal Vice Irregular Samples Vice Vertical Fastener Vice 32mm Round Vice 40mm Round Vice Adhering Surface Vice Double Saddle Vice All items below are included with the purchase of a PICO 155S ...

Страница 25: ...maintenance However to increase the life of the saw it is suggested that the cutting fluid be changed regularly weekly using a cutting fluid containing an anti corrosion additive e g DIACUT 2 cutting fluid After use it is also recommended that the unit be thoroughly rinsed and dried DIACUT oil based cutting fluid DIACUT 2 anti corrosion cutting fluid Remove and clean coolant tank replace with reco...

Страница 26: ...98 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com 5 2 Cleaning Outside Cabinet The cabinet and hood shield should be cleaned occasionally with a moist cloth Do not use any chemicals or cleaning abrasives 5 3 Service Panel For ease of service we have designed the PICO 155S to have a side access panel with the main electrical components on an easy to pull out rail s...

Страница 27: ...nnected from main electrical power supply b Main power switch is off c Emergency stop button engaged d Magnetic switch not engaged e Shut off switch engaged f Loose of broken wire g Unable to determine problem a Verify electrical source and connection b Turn on main power switch c Release by turning clockwise d Close hood or wiggle hood in closed position e Lift specimen holder arm or turn up shut...

Страница 28: ...AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com 7 0 List of Spare Parts Part no Description Images Mechanical Components P155 M 001 Aluminum Casting P155 A AS Arbor Shaft Assembly P155 M 002 50mm Blade Arbor Flange P155 M 003 75mm Blade Arbor Flange P155 M 004 Arbor Shaft Ring P155 A BBS Blade Spacer and Bolt ...

Страница 29: ...h St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com P155 M 005 Motor Bracket Spacer Tube P155 A COS Cut off Screw Contact Arm P155 M 006 Micrometer Shaft P155 M 007 Inner Micrometer Shaft Guide P155 M 008 Outer Micrometer Shaft Guide P155 A SSA Sample Support Arm P155 M 009 Sliding Load Arm ...

Страница 30: ...MANUAL 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com P155 M 010 Slighting Weight P155 M 011 Weight Rod P155 M 012 Weight 250g P155 M 013 Weight 300g P155 M 014 Counter Balance Weight P155 M 015 Counterbalance Rod P155 A PG Protractor Guide for Cutting Table ...

Страница 31: ... USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com P150 701 Blade Dressing Fixture P150 702 Sample Fixture Single Universal P150 702b Sample Fixture Universal Large P150 703 Sample Fixture Double Parallel P150 706 Sample Fixture Irregular Shaped P150 707 Sample Fixture ø32mm Round Mount P150 708 Sample Fixture ø40mm Round Mount ...

Страница 32: ...PICO 155S Precision Saw INSTRUCTION MANUAL 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com P150 709 Sample Fixture Adhering Surface P150 710 Sample Fixture Tear Drop 18 40mm 0 7 1 6in P150 711 Sample Fixture Fastener Fixture ...

Страница 33: ...2 6599 email pace metallographic com Web http www metallographic com Part no Description Images Sheet Metal Parts P155 F 001 Front Template Backing P155 A TA Cooling Tank Assembly P155 F 002 Cooling Tank Cover Tray P155 F 003 Motor Holding Bracket P155 F 004 Steel Cutting Chamber P155 F 005 Tank guide Roller Plate P155 F 006 Electronics Base Panel P155 F 007 2 Piece Tray Cover Right P155 F 008 2 P...

Страница 34: ...ecision Saw INSTRUCTION MANUAL 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com P155 F 009 Cover P155 F 010 Pump Cover P155 F 011 Cut Off Switch Cover Plate P155 F 012 Left Side Access Panel Door P155 CS A Magnetic Switch Holding Bracket ...

Страница 35: ...713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Part no Description Images Metalloid Parts P155 001 Power Supply Acrylic Cover P155 002 Magnetic Plastic Spacer P155 003 Acrylic Hood P155 004 Acrylic Hinge Spacers P155 005 Acrylic Dressing Fixture Cover P155 A CA Cutting Table Assembly P155 A CS Cutting Table Blade Guard ...

Страница 36: ...Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Part no Description Images Standard Parts P155 007 Belt Pulley P155 008 Micrometer Shaft Spring SN EX 8 Motor Spindle Snap Ring P155 009 Motor Spindle Locking Nut BB 12 28 12x28mm Bearing BB 8 16 6x16mm Bearing DB 8 10 10 Dressing Fixture Dry Bearing DB 7 5 8 Fastener Fixture Dry Bearing ...

Страница 37: ...Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com P155 010 Hood Hinge P155 011 Hood handle P155 012 Arbor Shaft Rubber Boot P155 013 Cut Off Switch Boot P155 014 Inner Cutting Chamber Seal P155 015 Outer Cutting chamber Seal P155 016 Outer Micrometer Shaft Guide O Ring P155 017 Dual Coolant Spray Nozzles P155 P 001 Brass Reducer for Pump ...

Страница 38: ...Z 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com PAN 18 26 18 Drip Tray M8 FEET Set of 4 Rubber Feet P155 TA C Rubber Gasket for Cooling Tank P155 018 Cooling Tank Handle P155 019 Side Panel Hinge P155 020 Cutting Table Brush P155 021 Brush for Tray Cover 1 P155 022 Brush for Tray Cover 2 P155 023 Thumb Screw M5 ...

Страница 39: ...nd safety guidelines 35 PICO 155S Precision Saw INSTRUCTION MANUAL 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com TOOL 2 5 ALLEN 2 5mm Allen TOOL 4 ALLEN 4mm Allen TOOL W 14 17 14 and 17 Combo Wrench ...

Страница 40: ...85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Part no Description Images Electronical Parts P155S E 001 Control PCB P155S E 002 Front LCD Screen P155S E 003 Motor Controller PS 24V 24v Power Supply TB RAIL Electronics Tray Rail 40MM FAN 40mm Cooling Fan PMP 24V PLD 24V Pump POW F SWITCH Electrical Switch With Fuse ...

Страница 41: ...A Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com POW E STOP E Stop Button FUSE 3A FUSE 1 5A 3 Amp Fuse 1 5 Amp Fuse SWT MAG IN Internal Magnetic Safety Switch SWT MAG EX External Magnetic Safety Switch MOT BLDC 150 150 Watt BLDC Motor SWT CUT OFF Contact Cut Off Switch P155 006 0 1 Micrometer C 110V 001 Standard 110V USA Power Cable ...

Страница 42: ...ety guidelines 38 PICO 155S Precision Saw INSTRUCTION MANUAL 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com C 220V 001 220V Round Pronged Cable C 220V 002 220V Flat Pronged Cable P155S T PICO 155S Template ...

Страница 43: ...on operating and safety guidelines 39 PICO 155S Precision Saw INSTRUCTION MANUAL 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com FIXTURES AND ACCESSORIES a b e f i j m n c g k o d h I p ...

Страница 44: ... installation operating and safety guidelines 40 PICO 155S Precision Saw INSTRUCTION MANUAL 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com q u y ac r s v w z aa ad ae t x ab ...

Страница 45: ...mm 1 6 inch Round Specimen Vise 1 j P150 707 32mm 1 4 inch Round Specimen Vise 1 k P150 706 Specimen Vise for Irregular Shaped Samples 1 I P150 710 Teardrop Holder 18 40 mm 7 1 6 inch 1 m P150 709 Specimen Vise for Adhering Samples 1 n P150 702 Universal Holder 1 0 P155 A SSA Sample Support Arm 1 p P155 A COS Cut Off Screw 1 q P155 M 009 Sliding Load Arm 1 r P155 M 010 Sliding Load Arm Weight 1 s ...

Страница 46: ...S In order to minimize cutting damage precision wafer cutting most frequently uses diamond wafering blades however for some materials the use of cubic boron nitride CBN is more efficient In addition optimal wafer cutting is accomplished by maximizing the abrasive concentration and abrasive size as well as choosing the most appropriate cutting speed and load Table III provides some general guidelin...

Страница 47: ...n 100 Low concentration 50 Figure 9 2 Metal pressed diamond and CBN wafering blades TABLE III Precision Cutting Blade Specifications In some cases precision cutting requires a coarser grit wafering blade Usually the coarsest standard blade uses 120 grit abrasive particles For metallographic applications coarse abrasives are mostly associated with electroplated blades Figure 9 3a The main character...

Страница 48: ... more frequently soft materials left and b alumina resin rubber blade right Perhaps the most important parameter for precision sectioning is the abrasive size Similar to grinding and polishing finer abrasives produce less damage For extremely brittle materials finer abrasives are required to minimize and manage the damage produced during sectioning Sectioning with a fine abrasive wafering blade is...

Страница 49: ...n also significantly effect a blades cutting performance Metal pressed wafering blades require periodic dressing in order to maintain performance A common misconception is that the cutting rates for these blades decrease because the diamond or abrasive is being pulled out of the blade In reality the metal bond is primarily smearing over the abrasive and blinding the cutting edge of the abrasive Wi...

Страница 50: ...713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Figure 9 6 Cutting performance vs wafering Blade conditioning Figure 9 7 Proper dressing fixturing will minimize damage to the wafering blade Table IV provides some recommended guidelines for sectioning a variety of materials ranging for very brittle to very hard and tough ...

Страница 51: ...Medium high General purpose Variable Variable Medium high 9 2 CUTTING PARAMETERS Most wafer cutting is done at speed between 50 rpm and 5000 rpm with loads varying from 10 1000 grams Generally harder specimens are cut at higher loads and speeds e g ceramics and minerals and more brittle specimens are cut at lower loads and speeds e g electronic silicon substrates see Table IV It is interesting to ...

Страница 52: ...id include Removes and suspends the cutting swarf Lubricates the blade and sample Reduces corrosion of the sample blade and cutting machine parts In general cutting fluids are either water based or oil based Figure 9 9 Water based cutting fluids are the most common because they are easier to clean however oil based cutting fluids typically provide more lubrication Figure 9 9 Oil based water based ...

Страница 53: ...cutting If appropriate clamp both sides of the specimen in order to eliminate the cutting burr which can form at the end of the cut For brittle materials clamp the specimen with a rubber pad to absorb vibration from the cutting operation Begin the cut with a lower force in order to set the blade cutting kerf Orient the specimen so that it is cut through the smallest cross section For samples with ...

Страница 54: ...s easily chipped or is braking Improper blade dressing Insufficient sample clamping Cutting force initially too high Use mechanical dressing fixture Secure specimen with rubber pad Reduce initial force to set cutting kerf Excessive blade wobble Cutting force to high Flanges dirty or not parallel Reduce applied force and or use larger diameter support flanges Clean or replace flanges Low cutting ra...

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