How to select the speed of a discocratic saw on metal. For pure cut

How to choose a carbide disk for metal?

So that after buying a saw disk, not to be disappointed in its resource and as a cut, you should pay attention to the following characteristics:

• Cleaning whether the disk is suitable in diameter to your saw;
• Catch in the number of maximum revolutions;
• Cleaning whether the disk is suitable for cutting your material.

Let’s analyze the first item briefly, the discs are of different diameters and here you need to know what disk diameter is suitable for your saw, the most popular diameters are 305 and 355 mm wheels.

The second point to which you need to take a very attentive, this is at what speed your saw works, since most of the TCs are limited in speed. For example, in a carbide saw saw 355×25.4 mm most often the maximum speed of 1600 revolutions per minute, and a similar abrasive disk 4400 rpm.

It follows that the discs are not interchangeable and, for example, at such saws as:

TC disks cannot be installed in these saws of the rotation speed of the spindle 3800 rpm.

The third point should also be attentively not only to the number of teeth, but also to the processed material.

Let us take as the basis of TST a disk with a diameter of 355 mm 80 teeth for steel cutting, such a disk is intended for cutting thin steel t.e. blanks with a thickness of not more than 3. 3.5 mm, for example, profile pipes with a wall thickness of 1.5 2 and 2.5 mm round pipes with a wall thickness of up to 3.5 mm, but this disk cannot be cut stainless and high.carbon steels. And, for example, TST disc 355 mm with 60 teeth is suitable for cutting steel with a thickness of more than 3.5 mm, for example, the rods of the squares and other similar blanks are where the thickness is more than 3.5 mm.

There are always information on high.quality carbide saw disks:

• Diameter;
• The thickness of the cut;
• Disk thickness;
• Landing diameter;
• The number of teeth;
• Maximum speed;
• Processing material.

In the picture below, we see how the marking on the saw disk is applied

• Disk diameter 305 mm;
• The thickness of the sawing cut 2.2 mm;
• Disc thick 1.8 mm;
• Landing diameter 25.4 mm;
• The number of carbide teeth 80;
• Maximum turnover per minute 1600;
• The disk is made in Japan;
• Stainless steel processing material.

In the picture below, we see how the tooth of tungsten carbide is attached

The tooth is attached qualitatively and sharpening at the highest level, which means that such a disk can be trusted.

• You need to choose a disk for a specific processed material;
• Be sure to pay attention to the number of maximum revolutions;
• Pay attention to the number of teeth, on 305 disk 60 teeth tell us that it cuts blanks with a wall thickness of more than 4 mm, and 80 teeth less than 4 mm.

In the next article, we will show the difference how the abrasive disk cuts and how it cuts a carbide disk.

If you have technical questions, you can contact us by phone 7 (495) 762-99-43

Features of the tool

“Circular” is a variety of disk saws. It is used for cutting metal sheets, rods, pipes, fittings. Driven by an electric engine. The tool is submersible, that is, it cuts metal not only from the edge of the material, but from an arbitrary point.

The design of the products is such that it is easily disassembled if it is necessary to replace or maintain parts. The only element requiring regular replacement is a cutting disk. It is made of alloy steel with an admixture of tungsten. Although the need to change the disk is dictated by the frequency and intensity of work.

The introduction of the electric motor and the ability to replace the reciprocating movement of the cutting canvas circular in a circular decades ago made a circular saw for metal a kind of innovation. Today, a powerful mobile device pushed into the background known analogues like a hand hacksaw.

Manufacturers produce models for the right or left hand. Some models are universal, that is, the user independently chooses which side the handle is located on. Disk saws are used in many areas. production, construction, as well as household needs. Equipment is selected according to a number of criteria for certain purposes.

Classification of circular saws

The main criterion for dividing circular saws into groups is the size of the cutting gear disk. This parameter also affects the power of the equipment and determines its cost. The larger the diameter of the disk, the more deep the cut is able to make the tool.

The second criterion is the depth of the cut, newly determined by the size of the disk. So circular saws are divided into 3 groups:

• from 4 to 5 cm (cutting sheet metal);
• from 5 to 7 cm (cutting of metal, profiles, small pipes);
• from 7 to 14 cm (professional equipment for overall or thick materials).

The third classification criterion is the power of the tool. 3 groups are also distinguished here (for household works, universal and professional models):

All models, regardless of power, allow you to cut blanks on both sides. Sometimes it is impossible to immediately perform a cut, so the circular saw is suitable for thick blanks.

The fourth criterion is the speed of the disk rotation. For household models, the indicator is about 3000 rpm, in professional it surpasses 5000 rpm.

Disk circular saws have a special disk design, which can be active and passive. In the first case, at the cutting element, the teeth bend in the direction of movement, in the second. against rotation. Circular for metal differs from analogues with a passive disk arrangement.

In addition to the listed criteria, gear and harmless devices are distinguished. The former has a transmission between the electric motor and a six.speed gearbox, while the saw disc is on the shaft of the last. The latter in the gear canvas is fixed immediately on the motor shaft. The pluses of gearbox models. the ability to adjust the depth of the drink, inclination of the canvas. The advantages of harmless circulars are compactness, lower weight and cost.

Another classification criterion is the ways to locate a saw at the workplace. There are stationary circuses mounted on a fixed bed. This makes it possible to cut long or wide material. Examples of devices-Einhell TC-TS 2025 U, Hitachi C-10 Re, Domestic Special SPS-21. The cheapest models cost 13-17 thousand.

Many differences of some saw from others complicates the choice of a suitable model. Further advice will be given at the choice, and some models of circular saw for metal will be considered.

Metal peeling saws

The name of the tool comes from its functions-the cutting disk by managing a person makes movements up and down, acting on the metal. In this case, the abrasive circle is lowered to the product subject to cutting, and at the end of the work it rises to its original position. It is possible to change the angle of inclination of the cutting blade (45 degrees turn).

Pension saws for metal are multifunctional. Some models offered by manufacturers cope not only with metal, but also with less durable blanks. For example, to work with a tree, it is enough to remove the abrasive disk and replace it with the circular of the corresponding diameter. In addition to wide functionality, the advantages of equipment are:

• obtaining a high.quality, accurate cut;
• accessibility and low cost of consumables;
• ease of work and replacement of elements;
• The speed of cutting process.

The main drawback of pendulum saws (also known as end) is their high products of this company are considered one of the best in the market, so it makes sense to overpay and get durable equipment.

The saw on the cutting of the metal has the following characteristics:

• power. 1650 watts;
• disk diameter. 260 mm;
• Disk speed. 4600/min;
• The maximum depth of cut at an angle of 90 degrees is 53 mm, at an angle of 45 degrees. 35 mm;
• weight. 11 kg;
• The amount of three measurements is less than 1.4 m.

The design is supplemented with a vacuum cleaner, a clip for a workpiece, guiding for ease of work. This detachment machine refers to network devices, so it has a 2.5 m long cable.

The price of a particular pendulum saw is determined by its power, depth and width of the saw, as well as additional functions. For example, the presence of backlighting, laser, blocking work in an emergency, the ability to connect a vacuum cleaner, and the presence of several speeds of operation.

According to these parameters, everyday from professional equipment differs. Good models for periodic work in home or garage conditions are models of Enkor, Caliber, Hyundai, Sturm companies! Professional models for long.term work with metal are considered machines for metal, Makita, Bosch, Metabo. In the 13-20 thousand range, you can choose a good pendulum cutting machine for cutting metal.

Features of installation saws

This tool is a compact portable cutting machine for metal. Unlike the previously considered equipment, the detachment disc only at a right angle, however, you can change the position of the processed part. For this purpose, the design of the mounting saw provides a clip in the form of a vice on which there is a device for setting an angle.

Classical saw. on the right; Dawed with cold reza. on the left

The main elements of the tools are platform (base), a desktop for the workpiece and the detachment disk (abrasive. in the case of metal). The cutting machine is classified by type of drive. It happens:

The first option is preferable for reasons of durability and security. In order not to overload the engine during long operations, the belt begins to turn, so the load weakens. A belt drive cars are more expensive than analogues with a belt, but they serve as an order of magnitude longer. For example, the cut-out disk saw of Makita 2414 NB with a direct drive costs from 11 thousand, while the COS-2200/400 chate with a belt will cost the consumer almost 25 thousand. Many parameters of both products are similar. a capacity of 2000 and 2200 W, the diameter of the disc 355 and 400 mm, the height of the cut 137 and 140 mm, respectively, however, it is the type of drive that is a decisive factor in the formation of the price.

The conditional division of installation saws into household and professional occurs according to two criteria. the capacity of the equipment and the type of drive type. So, a direct transmission tool is considered amateur, with a belt. professional.

The classic mounting disco saw for metal in action differs from the pendulum. The following are some features of the equipment for which the user must be ready before work.

• When cutting the workpiece at an angle, its displacement is possible. As a result, the disk is able to damage the bed of the product. In order to avoid this, it is recommended to use an additional clamp to fix the workpiece in a vice.
• The launch of the equipment is accompanied by a strong impetus. you need to be prepared for this.
• The cut.out mounting machine is a very noisy unit, so when cutting metal (especially prolonged) it is worthwhiles to use berushi or headphones.
• At the end of the work at the workpiece at the cutting site, a thin burr appears, which is easily cut off with a conventional corner grinder. It is recommended to have it ready.

Features of discs for aluminum cutting

Due to increased viscosity, non-ferrous metals are difficult to cut with discs designed to work on steels and cast iron. This is due to the fact that in the process of the chip is not discharged from the cutting zone, but clogs (sucks) the space between abrasive grains and filler. Therefore, for cutting pure aluminum and its alloys, special disks with softer and softer to paint are used by ligament. With this configuration of components, the cutting edge is better self.adjusted, although this increases the speed of wear of the tool.

Special discs for cutting aluminum produces only a limited number of manufacturers, the rest in the type of material usually indicate a wider purpose, for example, “for work on non.ferrous metals”. In general, the cutting of aluminum with a corner grinder makes sense only with some one-time jobs. And for large volumes of aluminum blanks, cutting and cutting machines with special sawing aluminum disks are much better suited. In the photo below: a disk for work on aluminum Metabo. Pay attention to the labeling of the hardness class (o means “medium.hard” and compare with the marking of the Luzhsky disk.

How to choose the right detachment disk

When buying a cutting circle for metal work, first of all, you need to pay attention to its diameter, t. to. It must accurately correspond to the type of angular grinder on which it will be used. In addition, the diameter of the landing hole should be correctly selected (22 or 22.2 mm). You should not worry about maximum speed and district speed, t. to. they are standard for each size. On all cut.off disks for Bulgarians, except for size and speeds, in the most prominent place is always indicated (text or icon), for cutting which material this sample is intended. If we are talking about metals, then four types are usually distinguished: steel, stainless steel, cast iron and non.ferrous metals. In addition, discs are produced both combined use (usually stainless steel), and for cutting individual non.ferrous metals, in particular aluminum.

Be sure to pay attention to the expiration date (it is knocked out on the rim of the bushings), t. to. Bakelite resins are used as a ligament in such products, which over time dry and lose their elasticity. You also need to understand that the discs for cutting metal of the same type, but various manufacturers behave differently during work during work. Therefore, so that there are no surprises, except for the analysis of standard data, it is necessary to look for additional information in the reviews of customers, on relevant forums, etc. P. The video below tells how several almost the same discs of various brands differ.

The step of the tooth

Quite often, the parameter “Step tooth” is confused with the number of teeth on the saw disk, meanwhile these are different characteristics. A step of teeth is the distance between two teeth (measured in millimeters), and this parameter when selecting a round saw must be first taken into account in the calculations.

With longitudinal sawing, the size of the tooth step should be sufficient so that from 2 to 4 teeth can fit into this gap in this gap. This is crucial in multi.digger machines, where saws are installed with a displacement of teeth. This configuration stabilizes the position of the saw canvas in the wood. The sawn blanket itself becomes a stabilizer. With transverse sawing, as well as sawing slab materials in the propyle of the tooth step, there may be a larger number of teeth.

Film to the tooth

Film to the tooth. This is a distance that passes on the work table for the processing period of one tooth, is measured in mm. This parameter determines, on the one hand, the roughness of the lumber after the saw and the maximum useful exit of the material for the life cycle of the saw disk.

This is an important factor for the election of cutting modes. The correct selection of feeding to the tooth is the key to extract the maximum useful output of wood from the entire life cycle of the saw disk.

Too small feed on the tooth will lead to overheating of the saw disk, each tooth heats up by friction, but at the same time the saw moves forward with each tooth cuts the heated area. With sawdust, this heat is discharged, t.e. The progress itself through the workpiece works as a cooling system. The higher the supply to the tooth, the less overheating of the disk, but the quality of the cut is reduced (t.n. roughness). In addition, too much feed to the tooth can bring to the outskirts (break) of carbide attacks or overflow of the interdental cavity cut off by chips.

You can calculate the feed for a sawda tooth by the formula

Thus, the supply to the tooth can be adjusted by increasing or decreasing the speed of the workpiece and changes in the number of teeth of the saw disk (we take the frequency of rotation of the drives in this case for a constant value, since we need to choose the saw and cutting modes for specific equipment, and not modernize the equipment itself).

Experienced way, through testing of many studies in the field of cutting wood and wood composite materials, the following optimal values ​​of the tooth filing are displayed:

What are the additional options

The design of each individual model is unique: manufacturers seek to improve their tools of various kinds of improvements. The most useful of them relate to three structural nodes.

First of all, the convenience and quality of the saw is determined by the design of the table for positioning. The guide rail has a rotary mechanism and graduation with an accuracy of 1, 5 or 15 degrees. If the corner pruning is often performed, models with quick fixation of the guide rail with a hand.colored flywheel that do not require any tool will be very useful. When cutting, the part is packed with a rotary sponge with a screw feed, which can have a folding lever for a faster fit for the size of the part. This node has always been considered a weak site of disk saws, therefore, with one.format cutting, it is better to give preference to a classic screw with a flywheel without additional options.

The second useful function is the electronic engine control system. It includes the function of a smooth start, which reduces the load on the electric network, and is additionally supplied with an electronic stabilizer that maintains the nominal speed, regardless of the applied load.

The third important node is a lever-hinge. It should be based on radial-index bearings and have a spring mechanism of self-return. In practice, the presence of a saw blocking handle in a position for transportation is very useful, cheaper and simple models use a regular chain for this.

How to choose a disk for a wood saw saw

Most often, endings are used just for processing wooden products and woodworking products. A suitable option for these materials should be selected in accordance with the hardness of the material and the result that you plan to get when sawing it.

For example, for solid wood, it is worth choosing specimens with an average number of teeth, and for the soft ones they are suitable for their smaller amount. The type of wood is also important. In cases of longitudinal and transverse sawing, you will need different disks models.

Which disk is better for end saw on wood.fiber slab

For sawing blanks made of wood.fiber slab, the same options are suitable as for thin wood blanks. And for wood, standard models with the number of teeth are usually used above the average and medium or positive angle of inclination to ensure a quick cut. Disk teeth are better that the trapezoid is located.

The main thing to remember: for a high.quality transverse saw, it is necessary to take into account the size of the product when choosing a saw element. Its recommended thickness is up to 4 mm.

Which disk is better for pure cut

To obtain even smooth edges, it is better to use options with a large number of teeth and a small thickness.

But it should be borne in mind that the larger the teeth on it, the less the number of its rotations in the same period of time, and the greater the load on the tool is going on. Therefore, determine first what is more important to you: a quick result or the presence of a clean cut.

Which disk to choose for the end saw on the laminate

To select a product for processing a laminate, you need to remember that the main criterion for the good work of the end when working with it is a pure and even cut that does not have roughness and chips.

It is better to choose a disk with very thin sharpening, with the presence of about 100 teeth and their trapezoidal location. The thickness of the saw disk should not be more than 4 mm.

Saw metal disks for end saw: how to choose

Exactly carbide products are suitable for work with metal, which have high strength and guarantee with proper use the long service life of their operation.

Sawing elements for metal must be selected depending on which metal you are going to saw, how important the smooth cut and the efficiency of the work process are important.

For non.ferrous metals, the most suitable options with a large number of teeth and a negative angle of inclination will be. For a quick saw, you can use options with a smaller number of teeth, which provides greater speed, but a more rough slice. When working with metal, models with trapezoidal sharpening are recommended when they alternately work for sawing and grinding the edge of the cut. See the article on how to cut metal on the end saw.

Basic terms in disk sawing modes of cutting

Скоростью резания при дисковом пилении называют путь, который проходят в одну минуту наиболее отдаленные от оси точки режущей кромки зуба диска. Скорость резания обозначается V.

В дисковом пилении диапазон скоростей, для большинства пил, колеблется в пределах от 60 до 300 м/мин.

Расчетная формула для определения скорости резания имеет вид:

где D – диаметр диска (мм) по наиболее удалённой от оси вращения точке режущей кромки; n. число оборотов диска (мм/об); Pi. 3,14.

Движение подачи осуществляется автоматически за счет перемещения шпиндельной головки по салазкам в направлении заготовки.

Подача в одну минуту — перемещение шпиндельной головки в миллиметрах за 1 мин., обозначается буквой S и выражается в мм/мин

Подачу на оборот — перемещение шпиндельной головки в миллиметрах за полный оборот диска, обозначается S0 и выражается в мм/об.

Подача на зуб — перемещение стола в миллиметрах за время, когда фреза повернется на часть оборота, соответствующую расстоянию от одного зуба до другого (на один шаг), обозначается Sz и выражается в мм/зуб.

Расчетная формула для определения величины подачи имеет вид:

где S0 – подача на оборот, мм/об; n – частота вращения диска, об/мин; Sz – подача на зуб, мм/зуб; z – количество зубьев диска, шт.

Скорость резания и подача не могут выбираться произвольно оператором диско-пильного станка по собственному усмотрению, так как это может вызвать преждевременное затупление диска, перегрузку и даже поломку отдельных узлов станка, нечистую поверхность обработки и т. д.

Перечисленные выше элементы резания находятся в тесной зависимости друг от друга. Кроме того, назначение скорости резания зависит от типа дисковой пилы и материала заготовки.

ТИП (ФОРМА) ЗУБЬЕВ

И зубья монолитных дисков, и резцы на твердосплавных пилах различаются по форме. Та или иная форма резца оптимизирована под определенные задачи. В зависимости от производителя тип зубьев может иметь различную маркировку, по сути же основные конфигурации одни и те же.

Предназначены для распиловки мягкой древесины, обеспечивают высокую скорость работы.

Зубья небольшие и часто расположенные, заостренной формы (как у ножовки)

Подходят для распиловки как мягкой, так и твердой древесины, скорость распиловки ниже, чем в предыдущем варианте.

Режущая часть напайки прямая (перпендикулярна полотну пилы), зубья имеют положительный угол наклона.

Применяется для продольной распиловки древесины.

Визуально схож с плоским резцом, но заужен книзу (форма трапеции). Диски с таким резцом имеют небольшое количество зубьев и комплектутся подчистными ножами.

Диски такого типа используются при обработке древесины в станках с потоковой подачей. Небольшое количество зубьев обеспечивает быструю скорость распиловки.

Плоские резцы чередуются со скошенными. Зубья имеют отрицательный угол наклона до 15 градусов.

Используются для выполнения маятниковой и радиальной резки. Благодаря отрицательному углу наклона обеспечивают качественный поперечный распил, но применяются и для продольной резки древесины, а также для обработки Древесно-стружечная плита и фанеры.

Зубья на кромке пилы чередуются. два скошенных в разные стороны резца и один плоский. Имеют положительный угол наклона.

Используются в переработке промышленных объемов древесины, обеспечивают быстрый и чистый пропил как мягких, так и твердых пород дерева, а также Древесно-стружечная плита. Чередующийся угло наклона позволяет применять эти диски как для поперечного, так и продольного распила. При выполнении заточки максимально высокого угла диски такого типа обеспечивают бережную работу с материалом, склонным к раскалыванию.

МОЖНО ЛИ ПОДОБРАТЬ УНИВЕРСАЛЬНЫЙ ПИЛЬНЫЙ ДИСК?

Очевидно, что подобрать дисковую пилу на все случаи жизни и под любой тип оборудования невозможно. Однако опираясь на характеристики диска вы всегда сможете подобрать пилу под конкретные задачи. Размер диска подбирается исходя из используемого оборудования, а при выборе остальных характеристик нужно отталкиваться уже от материала, который предназначен для пиления, направления реза (когда речь идет о древесине), планируемых объемов работ и т.д. Общие рекомендации по выбору пильного диска исходя из материала, предназначенного для пиления, можно обозначить следующим образом:

Для работы с этими материалами рекомендуется использовать твердосплавные пилы с переменными зубьями. Устанавливается диск на ручную или настольную циркулярную пилу либо торцовочный станок. Количество зубьев пилы может варьироваться от 24 до 60 шт.

ЛАМИНАТ, АЛЛЮМИНИЙ, ПЛАСТИК, ЦВЕТНОЙ МЕТАЛЛ

В обработке этих материалов хорошо зарекомендовали себя дисковые пилы с трапецевидной формой зубьев, имеющих отрицательный угол заточки.

При работе с древесиной дисковые пилы являются наиболее распространенным инструментом. При выборе пильного диска важно учитывать направление распиловки. продольное или поперечное. При пилении поперек волокон увеличивается сопротивление материала.

ПОПЕРЕЧНЫЙ РЕЗ. Предпочтительно использовать диски с большим количеством зубьев ( 60-80 шт.), имеющих отрицательный угол наклона. Такая конфигурация обеспечивает чистый рез. Для продольной распиловки такие диски не подходят. повышается вибрация оборудования, что негативно сказывается и на скорости, и на качестве распиловки и в конечном счете приведет к выводу оборудования из строя.

ПРОДОЛЬНЫЙ РЕЗ Рекомендуется производить дисками с малым и средним количеством зубьев, имеющим положительный угол наклона. На диске диаметром 230-250мм рекомендуемое число зубьев должно не превышать 18-24 шт. Большие впадины между зубьями способствуют выбросу опилок с рабочей поверхности.

В случае, если продольный рез осуществляется на многопильных станках проходного типа, следует учитывать высокую скорость распиловки, а также большие объемы переработки. Диски в этом случае больше подвержены перегреву, а это в свою очередь ведет к деформации. Поэтому на таких станках устанавливают пильные диски с промежуточными зубьями и подчистными ножами. Они вычищают опилку с рабочей поверхности, что защищает диск от перегрева.