band sawing: how to maximize cutting performance.

by:Gewinn     2020-02-15
Smart shopkeepers are beginning to realize that band saw cutting is an operation that, like a lathe or rolling mill operation, has the potential to make money.
But first there is a need to base on some factors.
Each material has its own characteristic and some unusual measures need to be taken in order to obtain satisfactory cutting performance.
For example, materials that are more difficult reduce the cutting speed.
The cutting speed will also decrease as the material can be cut down.
The surface conditions also affect the cutting speed.
If there is a hard place in the surface or material, the blade speed will slow down.
Each blade configuration has the best material width.
Under this width, the load on the teeth may become too large and the cutting speed must be reduced.
The blade control begins to decrease when the material width is greater than the optimum width.
For example, band saw blade 1 [inches]wide by 0. 035[inches]
The thickness of the best width of about 4 [will successfully cut the materialinches]. But a 1. 25[inches]blade by 0. 042[inches]
The thickness will have the best cutting stock of about 6 [inches]wide.
This is because the heavier blade has nearly twice the strength of the beam and can withstand higher pressure and cut the heavier material more directly. Best cut.
For each blade size, there is a \"best\" size for the material that can be cut
Allows the saw to cut quickly and provide the size of the maximum blade life.
This size is determined by the laws of physics that control the relationship between the distance between the guide of the blade and the stiffness of the beam.
There is a formula that can be found in any good engineering manual under beam deflection.
It takes into account factors such as Blade deflection, elastic modulus, inertia moment, load on the blade, and rail spacing.
It comes down to a 1 [inches]
Blades are good for cutting materials, up to 4 [inches]wide.
This is the ability to optimize \".
\"Working in the best performance range means that many things can be significantly lower than the best, and you will still get high quality parts and high speed production.
The blade sets a limit on the size of the material that can be cut.
These are not arbitrary rules for any manufacturer.
Of course, the size and quality of the saw determine the degree of control of the blade, the tension applied, and the degree to maintain alignment when cutting.
Therefore, the design of the saw is very important within the external limits set by bladedimensions.
Half of high quality
Inch machine can easily exceed the machine with poor qualityinch machine.
Since the blade only \"sees\" the material actually cut, the shape of the material cut will also affect the cutting speed.
There are special problems with cutting pipes, such as the blade having to enter the material twice, and it is almost impossible to keep enough cutting fluid flowing when the blade enters the second side.
Therefore, the cutting rate of the pipe is lower than that of the solid material. Guide spacing.
The stiffness of the blade is a function of the guide.
Obviously, the more exposed the blade, the easier it is to deflate.
For example, 2 apart from the tour guide [inches]
Except that the blade deflection may be around 0. 002[inches].
Under the same conditions, but the distance between the tour guides is 4 [inches]
In addition, the deflection of the blade is about 0. 016[inches](0. 002[inches]x 8[inches])and at 8[inches]
The boot interval is about 0. 128[inches](0. 016[inches]x 8[inches]).
All in all, the closer you can keep the blade guide rail, the more accurate the cut will be.
Sometimes you may be faced with the use of a blade smaller than the optimal material size, such as cutting a 10 [Blade]inches]
Round the saw equipped with 1 [inches]blade.
In order to reduce the possibility of excessive deflection of the blade, you may need to reduce the cutting force.
However, the cutting may stop completely if the material is hard or hard.
When cutting wide stock, a compromise must be found between too much cutting power and too little.
Trial and error may be the only satisfactory way. Blade selection.
The type, shape and condition of the material to be cut defines the type of blade to be used.
The owner should consider whether the material is a solid stick or a tube, or a structure, whether it is tied, and what kind of surface finish the material has.
Scale, rust and slag can cause problems that are difficult to cut.
There are many kinds of blade materials, from carbon to carbide.
Carbon sheets, hard ones.
Due to the poor heat resistance and wear resistance of the blade, the back and flexback cannot be generally recommended for production cutting.
In some applications, however, there may be hardened carbon blades for cost-effectiveness. Bi-
Metal blades make up the vast majority of blades used today, with many configurations, usually made of tool steel (M30, M42 etc)electron beam-
Welded on tough material against the mountain.
They have the largest versatility and use in the metal saw industry.
There are generally three types of blades: \"All
\"Use\" or matrix blades for soft steel, aluminum and construction;
Stronger and more resistant
Resistant blades for cutting foreign objects such as Inconel orWaspalloy;
And carbide blades, which are occasionally used to cut foreign alloys. The all-
The purpose blade is usually M-2 or M-
30 teeth, offering a combination of impact resistance and wear resistance.
These blades are sometimes called matrix blades and are very useful in cutting bundles and structures.
More difficult materials may require M-42 or M-
512 of dental tablets have a stronger wear resistance, but have a lower tolerance to impact. Carbide-
Tilt blades can be used to cut materials that are very wear-resistant or hard.
In the right application, the carbide blade with ground teeth provides a better finish and higher productivity than the traditional saw method.
Tooth geometry involves all aspects of the design of the teeth and the punch, including the front angle, shape, and settings.
Blades with \"offensive\" front corners, sometimes positive blades up to 17 degrees, are used in extremely hard steel that requires high penetration. The \"self-
The feeding properties of high raketooth generally allow for smaller blade pressures, allowing for straight cutting and longer blade life. However, self-feeding (
Mining materials)
Problems may occur when using this blade.
Soft materials such as soft steel.
Most modern blade designs have a slight \"hook\" pattern that helps the chip curl into small balls inside the gullet.
This helps to remove as much material as possible, just as the blade goes through the material.
The zero rake is a good tooth shape for the cutting structure.
This design adds resistance to impact and vibration.
The application of carbide blades is usually limited to extremely wear-resistant materials such as cutting titanium, as well as very tough, sturdy materials including nickelbased alloys.
In the right application, the carbide blade with ground teeth provides a better finish and higher productivity compared to the traditional blade.
Due to the sensitivity of the carbide blade to impact and vibration, it must be used very carefully and only on the band saw that provides weight and quality to properly control the blade.
Pitch requirements are generally determined by the size and configuration of the material.
The wider the material, the less temperature each inch.
However, when cutting structures such as wide flanges, more teeth are needed per inch.
A good rule of thumb is that the number of teeth cut at a time should not exceed 24 and should not be less than 4.
The Dental Group is the way the teeth \"bend\" from one side to the other.
Set helps provide clearance for the body of the blade.
In determining which type of blade to use, all three factors, namely, tooth shape, tooth spacing, and settings, should be taken into account.
However, it is almost impossible to have stock blades to cut various sizes, types and material configurations.
Compromise must be made.
Choose the blade that provides the best performance for the type of material you cut the most.
When using these blades on materials they do not design, be prepared to change the blade speed, cutting force and feed speed. Blade sharpness
You can\'t expect a blunt blade to cut straight.
When the blade becomes dim, it penetrates more slowly and generates more heat.
The extra heat will blunt the blade faster.
Since the dull blade cannot be detected by the naked eye cutting time, this is the most reliable indication of the blunt blade.
The cutting time increases significantly when the blade starts to become blunt.
It is worth noting that if the blade is too dark to cut stainless steel or similar materials effectively, use in soft steel may still be satisfactory.
For soft steel, however, too dark blades will not become a factory for aluminum.
It happens this way: when a very sharp point enters the material, it immediately begins to go deep into the material.
At some point it\'s too deep to \"bounce.
The next tooth does the same thing, causing vibration.
Excessive vibration will greatly reduce the service life of the blade, and will also cause excessive wear and tear on other parts of the saw.
When the blade starts to become slightly blunt, the point and vibration of the tap of teethstop stop.
Now, the teeth must be pushed into the material by means of a saw in order to apply the appropriate cutting pressure.
This \"honing\" process is best to carefully break on the new blade immediately after installation.
This is by reducing the cutting pressure on the blade to the minimum pressure required to achieve the cutting and gradually increasing the cutting speed until the required cutting speed is reached (
Square inches per minute)isachieved.
Generally, the blade breaking speed is not reduced in the new blade.
This will only increase the load on the chip and could actually cause the teeth to go deep into the material so that they break.
Reduce blade speed only to stop vibration with new blade.
Breaking the new blade carefully is the best way to get the maximum blade life.
The speed of the blade is usually limited by the vibration and the ability to keep the blade cool enough to avoid the darkening of the teeth.
A sword crown that runs very fast and cuts very shallow will soon become dim, as the tip of the tooth will overheat due to friction.
However, if we drill the blade teeth into the material, because the teeth are cut more and there is less friction, the blade will be less sensitive to heat.
Increased pressure can also prevent vibration.
So far, the higher pressure on the blade may actually allow a higher blade speed.
On the other hand, if we apply too much penetration, teeth will be torn off the blade.
The maximum feed rate is determined by the saw, material size, material shape, guide spacing, cutting fluid, and the size and shape of the tooth.
The larger the blade speed, the greater the feed speed, to the limit of the factors just discussed.
Pressure control.
The most effective cutting is done by cutting the pressure and the proper balance between the feed speed.
Soft, low-strength materials have different difficulties than hard, high-strength materials.
In soft, low-intensity material, it is unlikely to pull the teeth off the blade, but excessive
There may be a phenomenon of Flushing.
Using high strength materials, pulling out the teeth from the blade is a major problem.
Blade tension is an important factor in straight cutting.
Sufficient tension prevents the center of the blade from deflecting to the side, resulting in a curved cut.
The more nervous the better. Cutting fluid.
The importance of cutting fluid cannot be overemphasized.
The high quality cutting fluid in the band saw machine is one of the important factors of straight cutting.
But the band saw blade can only survive so much before it fails due to fatigue.
Whenever the blade turns, it is forced to wrap around the wheel, and at the same time, the blade is subjected to great tension.
Just run the blade without cutting anything, and the blade breaks after reaching the fatigue point.
It can be very sharp, but it will crack and break.
Similarly, a good coolant will help reduce the cumulative stress of the blade while running on the belt wheel.
Choose high quality cutting fluid.
Avoid a thin mixture of soluble oil.
Some new synthetic oils are very satisfactory in difficult operations.
If the ideal cutting and blade life is the ideal result, ask yourself a question before choosing the cutting fluid and mixture for your saw: \"Will I dig this material with this fluid?
\"The design and construction of the saw is clearly the key to maximizing production efficiency, reliability, ease of adjustment and repair, and optimal return on investment.
The blade guide rail should be an absolutely square anchor bracket and work as close as possible.
The column or \"Broken Head\" saw in the horizontal column saw must be very hard to prevent bending when the arm reaches its maximum capacity.
The saw arm must also be huge and powerful to reduce bending and allow proper blade tension. In a scissor-
The saw arm supports the type of saw of the blade guide rail, and the saw arm must have sufficient mass and beam strength to avoid bending.
It must anchor the blade guide arm to prevent them from deviating from the route and must allow proper blade tension and steering from the appropriate position where lateral movement is never allowed.
In a vertical saw, the arm itself must have sufficient mass and strength to allow proper blade tension to eliminate distortion and reduce vibration.
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