How to Achieve Optimum Cutting Power with a Metal Band Saw?
When metal band saw blade users purchase a new band saw machine for material cutting, they should learn more about the various performances of the band saw machine and the difference between the maximum sawing width and the optimal sawing width. “Okay. The instruction manual of this band saw states that the equipment has the ability to cut 250mm large materials. Let’s drag a 250mm solid stainless steel material here and see if it can be cut?” In this article, let us analyze the band. The actual meaning of the terms “maximum sawing capacity” and “optimum sawing capacity” of a sawing machine.
Optimal cutting size range for metal band saw
For each size of metal band saw blade, there is a size of material that is optimal for cutting: this size allows the band saw to cut quickly and provides the longest band saw life. This size is determined by guide block spacing and band saw blade stiffness. Anyone interested in the mechanics of sawing machines will find them discussed in the topic “Strength of Beams”. In engineering, a formula is used for calculation, in which the parameters include the deflection of the band saw blade, the elastic modulus, the moment of inertia, the load on the band saw blade and the guide block spacing. It boils down to a simple statement, that is, a 27mm band saw blade is suitable for cutting materials from 100mm to 125mm wide. This is the “optimal sawing width”. The optimal size range will give you the maximum blade life for a specific size of blade. When sawing within the optimal size range, virtually no skilled operator and a poor quality band saw blade can still cut the material successfully. Sawing within the “optimal” size range means that many factors can be less stringent and still result in high-quality parts and efficient blanking.
The Beam Strength of a metal band saw
To calculate any “beam strength” differences, simply cube the band saw blade width and calculate the difference, taking into account the change in band saw blade thickness ratio. Also, one must consider the additional downforce required when cutting wider cuts due to the increased thickness of the band saw blade.
For example:
Comparing a 34mm*1.06mm band saw blade with a 27mm*0.9mm band saw blade (27mm is the standard unit):
27mm: 1 x 1 x 1=100%
34mm: (34/27)x (34/27)x (34/27)=200%
+0.16 Increased strength from increased thickness: 18%
The strength of a 34mm beam is 218% of the strength of a 27mm beam
And so on:
The strength of 41mm*1.25 beam is 193% of 34mm*1.06
The strength of 54mm*1.6 beam is 256% of 41mm*1.25;
The strength of 54mm*1.6 beam is 123% of 54mm*1.3;
The strength of 67mm*1.6 beam is 191% of 54mm*1.6;
The strength of 80mm*1.6 beam is 170% of 67mm*1.6
All percentages above are approximate and do not take into account the additional downforce required to increase chip width.
The joint function of metal band saw machine and metal band saw blade
So let’s go back to the metal band saw on our 250 and plan on cutting out that 250mm piece of solid stainless steel. A 27mm band saw blade is used on the band saw machine. According to the principle of pitch selection, it is best to use 2/3TPI pitch and use an appropriate proportion of coolant. It is also best to let the operator know the difference between grinding and sawing. By the way, the band saw machine must be in perfect operating condition. It is best for the experimenter to bring a lunch, because this material is limited by the physical properties of the material itself, making it difficult to cut, and it still takes a certain amount of time to saw it off. Of course, the performance of the band saw machine determines the quality of the sawing. The metal band saw blade is limited by the band saw machine. How much tension can be applied and how to adjust it to the best position during sawing are all determined by the band saw machine. Therefore, in addition to the band saw blade specifications, In addition to the performance limitations, the design and manufacturing of the band saw machine are very important. A high-quality 250 band saw can easily outperform other average-quality band saw machines of the same specification.
Effect of the feeding speed of the feeding system on the cutting ability of a metal band saw
However, even the best quality band saw machine will be limited by the strength of the metal band saw blade itself, and cannot cut larger materials that exceed the strength of the band saw blade. If you want to cut larger materials, you should use a higher strength metal band saw blade. This is why metal band saw machines are manufactured in different sizes. The optimal saw size is selected to produce precise workpieces, maximizing metal band saw blade life and productivity. When sawing and blanking, the size of the material is equal to or close to the maximum sawable size of the band saw machine. The life of the metal band saw blade and sawing efficiency may be reduced by up to 50%. If it is only used occasionally, it is still acceptable, but If it is necessary to operate the saw machine at its maximum cutting capacity for a long period of time, even if a high-performance band saw blade is used and the band saw machine is operated under optimal conditions and the operator’s skill level is high, the following results can be expected: long sawing time, long metal band saw blade life short.
The feeding speed of the feeding system also needs to choose the optimal feeding speed, not the maximum feeding speed. There are many factors that affect the operation of a band saw. For example, even a skilled operator controlling the band saw may move back and forth from “best capability” to “maximum capability” even under ideal conditions. Generally speaking, you will want to choose the band saw and feed system that best suits your application. The capabilities of the feed system are matched to the phase saw and are designed to support the saw’s ability to cut the largest materials being processed. The maximum design cut size is the maximum size of material that the saw can cut, however, since large bars are often not straight and have weight concentrated in one area, this is not a practical cut size for heavy use. . The economic maximum is defined as the limit of the sawing capacity that the sawing machine can easily cut. Optimal sawing capabilities are those that can easily cut into materials regardless of surface condition or material straightness. For example, if a half-ton truck reaches its “design maximum”, it can carry 2.5 tons or more; at its economic ceiling, it can carry 1.2 tons; at its optimal load, it can carry 0.5 tons, and if it exceeds The half-ton limit makes it difficult to start and park the vehicle.
In summary
In short, when choosing a metal band saw, don’t be overly selective, especially for difficult-to-cut materials such as stainless steel, mold steel, titanium alloys, and high-temperature alloys. It is recommended to choose a larger band saw machine and a larger metal band saw blade. Otherwise, although the purchase cost of the band saw machine is saved, the subsequent operating costs will increase a lot, and the accumulation over a long period of time will far exceed the cost savings of the original purchase of the equipment.
