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Technical Inputs on Metal Cutting -Band Sawing

1. Types of Band Saw machines 2. Band Saw nomenclature CONTENTS 1. Types of Band Saw machines 2. Band Saw nomenclature 3. Band Saw Selection 4. Band Saw Cutting Condition 5. Band Saw Testing Report 6. Trouble shooting.

TYPES OF BAND SAW MACHINE & APPLICATION HORZONTAL；１３２０Ｈ×１７２０w VERTICAL；１２６０Ｈ×1560w×４０００ Construction Beam TYPES OF WORK MATERIAL Bearing Steel Bars Tool & Dies

METAL BAND SAW MACHINES Cut-Off Machine Contour Machine Hinge Type 2 Pole Vertical Down Type Portable Machine

Tooth material ＆ B.M.Construction 刃部材質とﾊﾞｲﾒﾀﾙ構造 　Tooth　material　＆　B.M.Construction　 ・Tooth material is made of Powder HSS or Super HSS. ・Body material is made of spring steels. ・Tooth and body are welded strongly by electronic beam welding.

PITCH WIDTH TOOTH Rake Angle Wedge Angle Cutting Face Gullet 各部の名称 　NOMENCLATURE Rake Angle Wedge　Angle 　Back　Angle Cutting Face Gullet Gullet　Depth Thickness Set Width PITCH WIDTH BACK TOOTH BODY=SPRING STEEL

Ｔｏｏｔｈ ｆｏｒｍ Types of Tooth Form Tooth Form ● Regular Tooth Form 　Ｔｏｏｔｈ　ｆｏｒｍ　 Types of Tooth Form Tooth Form ● Regular Tooth Form 　・Wide application of materials, like Carbon Steels, Alloy Steels & FC 　・０°rake angle is suitable for small diameter less than 50mm and thin plate. 　・4T, 4/6T & above (Fine Pitch Tooth) ● Hook Tooth Form 　・Hook tooth form has sharp teeth permits good cutting performance. 　・Positive rake angle is suitable for tough and non ferrous materials. ・3T, 3/4T & below (Coarse Pitch Tooth) 0 degree rake Positive rake

　ピッチ 　Ｔｏｏｔｈ　ｐｉｔｃｈ　 Tooth Pitch is defined as the number of teeth per inch (TPI) Pitch Type Pitch Pattern ● Constant Pitch Constant pitch has uniform tooth spacing. - Use for solid material. ● Variable Pitch (VL) Variable pitch has different Variable pitch has 2 types of pitch in one group. Variable pitch produce less noise and reduce vibration 1 INCHES Constant Pitch 3 TPI 3 TPI E.g. of 3TPI 25.4 ÷3TPI=8.46mm Variable Pitch 2/3 TPI 1 GROUP 2 TPI 3 TPI

　あさり形状 T y p e o f t o o t h s e t　 Tooth Set: The teeth are alternately protrude on the left and right of the band body. It’s allow clearance of the blade back through the cut. 　Type of Tooth Set Tooth Set Pattern ● Standard Tooth Set 　・Used in constant pitch. 　・3 teeth sequence – left, right & straight. ● Group Tooth Set 　・Used in variable pitch. 　・Multi-teeth sequence. - Prefer for ferrous material ● Wave Tooth Set 　・Used in fine pitch tooth. ・Suitable for sheet metal, thin pipes. 3 Tooth Set 5 Tooth Set 7 Tooth Set Wave Tooth Set

　あさり形状 Cutting Performance　 Cutting Performance primarily depends on following factors Machine Design and Quality Work Material composition Material size and shape Guide spacing Blade TPI selection Blade sharpness / Tooth Profile Blade speed and feed rate Blade tension Blade Vibration Coolant Quality and Proportion

TPI Selection Standard Band Saw Pitch Reference Table as below Pitch too big -- cutting force increase in per tooth -- causes tooth break & bad finishing Pitch too small -- chips stuck in groove of tooth -- causes breakage of band saw Soft & elastic materials -- better to use slightly coarser pitch Hard materials --better to use fine pitch W

NACHI Metal Band Saw Selection Tough to cut Easy to cut

Cutting Speed -- Movement speed of Band Saw in 1 min as m/min Cutting Condition Cutting Speed -- Movement speed of Band Saw in 1 min as m/min based on the work materials to be cut Cutting Rate -- Work piece area being cut in 1 min as cm2/min Cutting area cm2 Cutting Rate cm2/min = ------------------------ Cutting Time min Cutting Speed m/min Cutting Time　min Cut Area　cm2

SWORD PERFORMANCE SAWING S45C Cutting Condition ・Material：Machine Structural　Ｓ４５Ｃ 　Φ３００ ・Band Saw Size： SH　４５７０×３４×１．０７×２／３ ・Machine　　 ： HA-４００ ・Cutting Speed ： V＝５５ｍ/min　 　 　　　　 ・Cutting Time ： １３分/min（Rate＝５４cｍ２/min）　 ・Result　　　　： Total area of cut　ｃｍ２ SAWING S45C （ｃｍ２） AMADA Bhaco

SWORD PERFORMANCE SAWING SKD11 Cutting Condition ・Material：Cold work tool steels　SKD11 　Φ200 ・Band Saw Size： SH　４５７０×３４×１．０７×２／３ ・Machine　　 ： HA-４００ ・Cutting Speed ： V＝40ｍ/min　 　 　　　　 ・Cutting Time ： 14 . 5分/min（Rate＝22 cｍ２/min）　 ・Result　　　　： Total area of cut　ｃｍ２ SAWING SKD11 （ｃｍ２） MARATHON M42 SANVIK

TIPS FOR OPTIMUM PERFOMANCE 1. Breaking-in or running-in of a new blade is important. 2. Avoid starting a new blade in an existing cut. 3. Apply correct tension. 4. Observe chip formation. Fine, powdery chips mean insufficient feed pressure. Coarse, heavy burned chips mean excessive feed pressure. 5. Ensure proper clamping of work material. 6. Position guide arms as close to the work as possible. 7. Ensure correct position & condition of wire brush. 8. Use correct proportion of coolant.( 5 to 10 % oil )

MACHINE RELATED TIPS Check Carbide guides, replace worn out guides. Check Blade tracking, proper gap between blade back & band wheel flange to be maintain. Check free movement of blade in guides. Maintain proper pressure of guides on blade. Check coolant & hydraulic oil level. Check oil & coolant leakages if any. Clean oil filters periodically. Check blade alignment with respect to vise & base. Use ½ capacity of vise for optimum life.( Better beam strength )

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