Do-it-yourself band saw – the drawing is not as scary as its implementation. Band saw for metal

home

Systems

Equipment, even the most advanced, will be ineffective if components limit its capabilities. Band saw blade different types and purpose allows you to cut almost any workpiece from various materials.

1 Blades for bandsaw machines - types and designs

For modern metal workers, the market offers blades made of carbon steels, as well as bimetallic blades with a spring base and teeth made of carbide or high-speed steel. The variety of designs of band saws and the use of optimal cutting modes make it possible to ensure sufficiently high productivity and significantly reduce the cost of metal processing using band saw equipment compared to other methods of separation cutting of workpieces.

Band saw blades, made from quality high carbon tool steel, are designed to handle a wide range of unalloyed and alloyed alloys. However, in terms of their operational and technical indicators, they are significantly inferior to bimetallic band saws, which have become more widespread, especially with high-speed steel teeth. The base of these blades is made of special spring steel, which provides the saws with strength and durability.

The cutting (working) part of the teeth is made of high-speed alloy M42, which is an analogue of 11Р2М10К8. This steel, alloyed with cobalt and molybdenum, has high (up to 950 HV) hardness, wear and red resistance. Reliable connection basics with cutting teeth is provided by electron beam welding and allows the use of bimetallic sheets in the most difficult production conditions. Saws of a new design, having a combined tooth pitch, are most suitable for cutting products of variable cross-sections, profiles, and pipes.

The variable pitch can significantly increase efficiency and stability, and reduce vibration in the cutting process of various workpieces with variable cross-sections.

Band saws with carbide teeth are used for the most difficult cutting conditions. They are used on rigid double-column and high-performance band saws when cutting difficult-to-cut materials:

rare earth metals;
non-ferromagnetic alloys;
iron casting;
alloys such as Hasteloy, Inconel, Monel;
other alloys with high titanium and nickel content.

The use of these blades can significantly reduce cutting costs. Carbide plates are installed in special sockets, the design of which guarantees the reliability of their connection to the saw blade. The tooth alignment provides the required clearance during the sawing process and necessary removal shavings. These belt blades are used only for processing solid-section workpieces with a diameter of 60 mm or more.

2 Technical parameters of band saws

To achieve the most optimal conditions When processing certain types of materials and shapes of cut workpieces, it is necessary to precisely select the technical parameters of the blade: shape, setting and tooth pitch. Also important are the operating modes of the band saw itself – feed and saw speed.

The tooth pitch of the blade is determined by the number of teeth (TPI) per 1 inch (2.54 cm). TPI for saws with a constant tooth pitch can be from 1 to 32, and for blades with a variable tooth pitch it varies from 10/14 to values of 0.75/1.25. Band saw manufacturing companies and their distributors for the right choice Their products include guidelines for selecting tooth pitch when processing solid workpieces, profiles and pipes.

Setting - the angle of rotation or inclination of the teeth relative to the plane of the blade, ensures free movement of the tooth edge and strip fabric. The following types of wiring exist:

Standard, consisting of a repeating combination of tilting the teeth - first to the left, then to the right and straight. Can be used for all types of steel, especially often when sawing soft materials(non-ferrous metals, wood, plastic).
Variable – a few teeth to the left, a few to the right, a cleaning tooth. Characterized by reduced noise and vibration, it is used for cutting products with variable cross-sections, profiles, pipes, metal packages.
Wave – for processing thin-walled pipes and profiles, small-diameter products, and other thin materials.

Tooth Shape:

NORMAL (N) – the rake angle of the tooth is 0°. Blades with this shape are intended for processing alloys with a high carbon content (cast iron, for example), materials with a small cross section, as well as thin-walled pipes and profiles.
HOOK (H) – the front angle of the tooth is 10°. These saws are designed for cutting solid bars made of alloy steel.
RP – angle 16°. The blades are used for aggressive processing of solid rods and workpieces made of high-alloy steels, difficult-to-process non-ferrous alloys and metals.
MASTER. The front angle tooth is made in two types – 10° and 16°. It has a longitudinal chamfer obtained by grinding, which improves the roughness of the processing surface. These saws are designed for cutting bars and solid profiles made of high-alloy steels.

3 Main parameters for proper operation of the belt web

The cutting mode (speed and feed) is determined by several important indicators:

workpiece material;
what group of alloys and steels does the material belong to;
workpiece size.

Based on these data, the tooth pitch is selected. To determine the cutting mode, it is also important which company manufactured the band saw blade. Sellers of band saw equipment provide recommendations on the optimal blade speed for a particular type of machine. European-made units have proven themselves well, equipped with a stepless speed variator, which allows you to select the optimal cutting mode for a specific type of material.

In addition, such equipment can be additionally equipped with a built-in blade tension control device (tensometer), which is also important for significantly increasing the life of the band saw. The feed rate is determined from the following considerations. For optimal cutting, it is necessary that each individual tooth of the blade cuts chips of a certain thickness provided by the design.

In practice, the feed is selected in accordance with the recommendations of machine tool manufacturers, or according to the type of chips formed during cutting. When the chips turn out to be dusty or thin, the feed speed needs to be increased or the cutting speed reduced. Blue or thick chips indicate overfeed or a need to increase cutting speed. Slightly curly - means that the sawing mode has been selected correctly.

4 Durability and choice of metal band saws

Saws are characterized by resistance to wear of both the tooth and the blade itself, which experiences alternating signs cyclic loads, arising during its movement in the tape transport mechanism of the machine. For products from most manufacturers, the service life of the belt web is 140–160 hours of continuous operation of the equipment (subject to all technological stages the manufacturing process of the canvas - from its preparation to packaging of the finished product and storage conditions).

Removing the saw during breaks in the operation of the machine provides the so-called relaxation of the blade, which somewhat extends its service life. The durability of a tooth is significantly influenced by its correctly selected pitch, determined depending on the diameter of the material being processed. When cutting a package of products, the diameter and wall thickness is taken as the total thickness of the entire metal that will be cut. When cutting adjacent pipes, double the wall thickness is used. Below are tables for determining the saw tooth pitch.

For independent choice types of bimetallic tapes are guided by the following simple rules:

for work with low-carbon and carbon steels, PROFI M42 saws are used;
for processing high-carbon alloys and steels – SUPER M51;
for wear-resistant, heat-resistant, heat-resistant and exotic alloys - type SP.

For cutting special alloys that are difficult to machine, hard materials and materials with a heterogeneous structure, carbide saws of the TCT type are used.

Saw pitch size for cutting solid steel

Saw pitch size for cutting profiles and pipes

Currently, our company, having many years of experience in supplying band saws to Russia, occupies a leading position in the manufacture and sale of saws. We work only with trusted suppliers: Simonds, Lenox and DoAll. Confidence in the quality of the products supplied allows us to provide a lifetime weld guarantee.

American ribbon fabrics Simonds, Lenox and DoAll are rightfully considered one of the best. They are used for sawing on sawmills, vertical, horizontal and band dividing machines. The blade blades of these manufacturers provide smooth and accurate cuts in wood, plastic and metal materials.

From us you can buy a band saw blade, as well as ring-welded band saws for both wood and metal at the best price!

The uniqueness of the alloy used in the production of the canvas is
patented saw body hardening methods,
exclusive shape of band saw teeth

In conditions of small-scale production, only metal band saws can best cope with the tasks of cutting a diverse range of rolled products. Therefore, they are an indispensable attribute of many procurement industries. Today, we will dwell in detail on the parameters of band saws, talk about the device and manufacturers.

Manufacturing tasks solved with metal band saws

This equipment is typically characterized by a straight, narrow endless saw blade that moves in a circular path. The blade orientation of a metal cutting saw can be vertical or horizontal. The cutting action is achieved through continuous movement along an arc of a closed saw blade, while simultaneously pressing the workpiece against the blade.

The device of the metal band saw provides the ability to quickly change shape and size final products taking into account the strength characteristics of the workpiece material. With a large range of rolled metal products to be cut, band saws are almost ideal equipment.

Unlike the force or thermal effect due to which friction saws or sheet shears with an inclined knife, band saws perform dynamic cuts, the parameters of which can be easily and quickly reconfigured. This reduces wasted time.

Most often, metal band saws are used for:

Separation of metal along a complex contour with an optionally clean cut surface, since the joints will subsequently be welded into a specific structure. In particular, cutting along parabola, ellipse and similar shapes is successfully performed.
Straight and angular cuts on metal rods, pipes, rolled profiles, both tubular and solid cross-section.
Separation of workpieces made of metals and alloys with different indicators of strength, hardness and elasticity.

Thus, in terms of the ratio of production capabilities and price of devices for mechanical cutting of metal, modern band saws have an advantage over less universal ones circular saws. Tool life is ensured by the continuous supply of coolant to the processing zone.

Classification

Modern metal band saws differ:

The direction of movement of the tape web can be in the vertical or horizontal direction.
Drive power - distinguished compact machines with a power of up to 2000...2500 W, and stationary, with a power of over 2500 W.
The speed of movement of the saw blade (it can be constant, which is practically no longer used in modern machines), or variable from 10 to 100 m/s.
The design of the saw blade itself, in particular, its material (it can be ordinary tool steel, high-speed steel, bimetal, hard alloy), as well as the pitch frequency of the teeth along the length of the blade (30...80 m -1). The width of the saw blade also varies. For particularly powerful models that, in addition to actual cutting, also trim the end of the blade blank, they can be double-sided.
The structural layout of the band saw machine, which can have a single- or double-column design.
The degree of automation of the metal cutting process. On a metal band saw equipped with CNC, the speed of movement of the saw blade is controlled by automation, which is adjusted depending on the material being cut and its hardness.

The operating principle of a metal band saw is as follows. The working body of the saw is a flat flexible blade with teeth, which is welded into a continuous strip. This belt is put on two pulleys, one of which is drive. When the drive is turned on, the blade begins to move and cut metal with its teeth. The material being cut is constantly fed into the cutting zone at a certain speed, providing the necessary pressing force of the workpiece to the teeth of the saw blade.

Device of band saws for metal

It is determined by the purpose and layout of the machine. Let's look at the options most often offered by manufacturers.

Double Column Semi-Automatic Band Saw Manufactured by Indiamart. Its feature is hydraulic blade tension and a hydraulic clamp, which is equipped with a hydromechanical sensor. The speed of movement of the saw blade can vary within wide limits, since the drive uses a motor alternating current with variator. The blade has high quality, which ensures the execution of cutting and trimming operations. The use of such a band saw is effective in various industries economic activities: from the automotive industry to the production of building metal structures.

Fully automated two-column band saw from Irlen-Engineering (Russia-China). The peculiarity of this machine is the workpiece separation speed that can be varied over a wide range, good blade tension, excellent motor ability, a capacious hydraulic reservoir, and the ability to be used when cutting metal of different strengths.

Vertical single column band saws from the Czech company Proma. The peculiarity of such equipment is convenient access to the workpiece and tool from three sides, high cutting accuracy, and high quality of welded connections between parts of the saw blade. The machine is a semi-stationary type and can easily be moved from place to place.

Metal band saws model range jet (Taiwan). The machine implements the classic concept of straight cutting, which is why such equipment is often called mechanical hacksaws. The design of such machines includes a swinging frame and a crank mechanism, which ensures reciprocating movement of the saw blade. In terms of productivity, such machines are inferior to continuous band sawing equipment.

Band saws from Enkor (Russia). Domestic producers The equipment under consideration with conventional controls is represented by machines of the Corvette model range, which also belong to the class of mechanical hacksaws for metal. The machines are equipped with the necessary control and measuring devices, allow you to optimize the cutting speed, and are equipped with highly resistant saw blades.

The obvious advantages of band saws for metal are the speed of changing technological cutting parameters, compactness, and the ability to configure the tool for cutting various metals. The price of equipment is determined by its power and functionality. It amounts to:

For saws with manual supply of material - from 16 thousand to 50 thousand rubles;
For semi-automatic saws - from 85 thousand to 280 thousand rubles;
For automatic metal saws with CNC – from 600 thousand to 1.3 million rubles.

Band saws are an indispensable tool in the production of complex shaped parts. The specifics of the enterprise predetermine the configuration of the equipment, its operational characteristics and the choice of used Supplies. Work efficiency depends on the right choice the desired model And economic feasibility applications. To do this, you need to know the capabilities of band saw equipment and the principles of working on it. Belt blades can be made of various types of steel, have a certain pitch and set of teeth.

Application area

For each type of work, manufacturers try to offer a selection of products with clearly defined qualities. Band saw equipment is widely used in metalworking, woodworking, and construction business. We carry out cutting of plastic and composite materials. Ferrous and non-ferrous metals are processed. Band saws are universal. By replacing the brand of blade, its pitch and cutting modes on the same equipment, you can effectively produce parts from completely various materials. This ensures high accuracy, minimum waste and high speed performing operations.

Classification

The division into types of band saw tools is made according to several basic parameters. This special purpose canvases. When choosing, it is taken into account what material the product is intended to work with:

Wood saws. Sufficient wear resistance and sharpening quality are important. The part after processing must have an even cut with a minimum tolerance for finishing operations. For woodworking operations, the blade is available in a special version. The pitch of the teeth, the width of the strip and the strength characteristics of the steel were calculated. When worsening performance qualities Repair and sharpening are allowed.
Metal saws. Depending on the strength of the material being processed, a model of band saw blade with the necessary parameters is selected, such as sufficient strength of the cutting part, length and pitch of the teeth.
Universal canvases. They are designed to work with materials of different structure and strength. One saw can work on both metal and wood. While there are obvious advantages, there are also significant disadvantages. Such canvases will be inferior to specialized products with a narrow focus. It is advisable to use such band saw equipment only for a variety of work in workshops and small workshops, where such a choice will be fully justified. Somewhat worse performance indicators are compensated by versatility. There is no need to reconfigure band saw equipment or change the blade. Several modifications are available with various types cutting edge and tooth pitch, made from various grades of steel. The width of the canvas is divided into standard sizes from 6 to 54 mm.

The quality of the cutting part is of no small importance. Depending on the material of manufacture, the canvases are classified as follows:

Cutting technology

The main advantage of working with a band saw is productivity and a number of operations that are unattainable when using circular machines and equipment with a reciprocating operating principle. The ability to change the motion vector during the cutting process makes it possible to process curved surfaces with high accuracy. A valuable quality in carpentry, where when working on wood it is often necessary to make parts of complex shapes. Band blades are also effective when cutting profiles and pipes. In terms of popularity of use, such equipment competes with other devices of a similar class. If damaged, repairs can be made to fully restore performance.

The cutting principle is continuous movement cutting blade made of steel welded into a ring in a special mechanism. This provides a number of operational advantages. The clamping force is directed downward, and the lack of reverse motion makes additional fixation of the part unnecessary in some operations. Often when working on wood, the part is held in the hands, and the cut is made according to the marks. The main disadvantage circular saws, with all their advantages, is the impossibility of making a curved cut and the absence of its vertical line. The cut location is always radial, repeating the angle and diameter of the disk. The tape is free of these shortcomings. The cut is along the entire length and the edge is strictly vertical, perpendicular to the plane processed material. Cutting methods depend on the band saw model. Modern versions are equipped with the necessary additional equipment and equipment for automatic or semi-automatic operation.

Production technology

The main task in the manufacture of a tool is a high-quality joint when forming a loop from a workpiece.

The tape is supplied from the manufacturer in a coil in one piece. Then it is cut into pieces and welded with a special machine. ready product. Ideally, after stripping and sanding the joint, this place should not be noticeable. Production is demanding in all respects. The fabric should not lose strength, the roughness of the tape should not exceed acceptable standards, and the shape and pitch of the teeth are preserved.

The choice of products with different lengths, thicknesses, and tooth pitches is quite large. The production tries to offer the maximum selection of canvases for the user with certain geometric and performance characteristics. When purchasing, you must carefully analyze the tables with recommended saw parameters for specific types of work. The characteristics of the band saw machine on which the blade is placed also have great importance. Belt speed and feed of processed material are basic technical parameters, based on which the optimal saw models, tooth pitch and setting are determined.

Sooner or later, the tape loses its quality and needs to be replaced, but installing a new tape is not always cost-effective. Having a significant resource in terms of its strength characteristics, it is economically profitable to send the tool for repair. The band saw is freed from the saw, which will be operational again after certain operations. The main task is to restore the cutting ability of the blade. To do this, the necessary procedures are determined:

Welding. It is used when the integrity of the product is compromised, part of the teeth is lost or other serious damage occurs. When welding, the grade of steel and the joint location are taken into account, the requirements for which are the same as in industrial production.
Cleaning. During operation, sticking of melted particles of the material being processed, scale and other foreign substances is possible. This makes cutting very difficult and degrades its quality. The decrease in working qualities does not affect the main production best influence. After cleaning, the blade is suitable for installation in a band saw. This type of repair is often carried out on site.
Sharpening. The cutting edge is restored using an abrasive tool. In this case, the pitch of the teeth and their shape must remain the same. Violation of the geometry of the saw will lead to a change in its performance characteristics.
Wiring. Required quality for free movement of the belt in the processed material. Under load during operation, the deviation of the teeth from the blade, specified during production, decreases. The saw begins to “bite” or it begins to deviate from the movement vector to the side. Correct wiring will return the required performance.

All types of fabric can be repaired, and simple models for wood, and bimetallic band saws for hard steel grades. Tool refurbishment improves key economics, making production more cost-effective.

- This cutting tool, used for band saw machines. By its design, a band saw has the appearance of a flexible steel band, tightly looped, with a row of teeth along one edge.

The band is mounted on two pulleys, which are rotated by the electric motor of the band saw.

Using a band saw, you can make both straight and shaped cuts. That is why the scope of its use is very diverse and is not limited only to furniture production.

Types of band saws

Band saws can be divided into the following kinds:

toothed;
toothless;
electric spark principle of operation.

Toothless Band Saws And electric spark saws The actions work similarly to circular saws. The only difference is the purpose of the teeth.

When choosing a band saw for metal, you need to pay attention to the design features of the band saw machine.

The main purpose of a metal band saw – this is the execution of angular, straight and figured cuts. If you need to make cuts at an angle, you will need to purchase special rotary jaws for this machine.

Characteristics and properties of the band saw

The main properties and characteristics of the saw are:

height and width of cut;
type of cutting blade;
electric motor power;
total weight of the machine and diameter of the pulleys.

up to 300mm – light;
from 420 to 500 mm – medium;
with a pulley diameter above 500 mm - heavy.

Lightweight bandsaw machines are equipped with electric motor up to 2 kW, medium and heavy electric motor up to 4 kW.

Blade Types

For cutting with a saw, special requirements are placed on the strip blade.

For cutting metals, bimetallic blades consisting of two metals are used. The main part of which consists of a metal strip made of special spring steel, and the working part consists of tool steel with sharpened teeth.

Carbon steel blades are widely used. According to their heat treatment, tape fabrics can be divided into the following types:

with the same hardness across the entire width;
with flexible blade and hard teeth;
tempered blades over the entire width.

Blades with the same hardness across the entire width work well on medium-diameter pulleys. The Rockwell hardness of the sheets is 47 units.

Saws with a flexible blade and hard teeth have a specific structure. Only the upper half of the tooth will be hardened, leaving saw blade flexible. The Rockwell hardness of the saw body is 31 units, the hardness of the teeth is 64 units.

Saws with a hardened blade over the entire width are the most popular. Their Rockwell hardness is 52 units, and their tooth hardness is 67 units.

Due to the high hardness of the teeth, the resistance to dulling is significantly increased, and the increased rigidity allows for cutting at high speeds.

Sharpening band saws for wood

When cutting wood or metal, the teeth of a band saw may lose their original sharpness. This is why you need to sharpen your electric band saw.

Sharpening the saw blade is as follows::

initial sharpening;
cleaning;
wiring;
final sharpening.

To restore the cutting qualities of the saw blade teeth, use special sharpening machines.

As a result initial sharpening you will eliminate all cracks in the teeth’s sinuses, and also restore the profile teeth maintaining a certain symmetry to the rest.

When cleaning All metal filings remaining after sharpening are removed.

When wiring change angles.

During final sharpening correct symmetrical distortions of angles and sharpen the working edges of the teeth.

Sharpening saws with your own hands will require you to have certain skills and abilities. Therefore, if you are not sure of the quality of your work, leave this matter to the specialists.

Professional sharpening will restore the perpendicularity of all cutting edges.

Sections