Circular saws for wood
A circular saw is a rotating cutting tool in the form of a circular blade with many cutting teeth around the perimeter, which is designed for mechanical cutting of wood and wood-based materials.
The circular saw is made of alloy tool steel, heat treated, aligned, calibrated, set and sharpened.
-
Material: The circular saw is made of 75Cr1 steel. (DIN 1.2003); (ČSN 19418)
heat treatment: Saw blade hardened to 44-48 HRc for body thicknesses up to 3 mm and 42-46 HRc for body thicknesses over 3 mm.
The runout of the saw blade changes in the clamped state near the fastening hole, and it is necessary to pay attention to the quality of the clamping flanges, which must be at least 5x√D saw diameter.
Calibration: By properly adjusting the preload, the strength of the circular saw blades is increased, which allows for higher feed rates and thus higher cutting accuracy and surface quality. Circular saws are calibrated during manufacture for a cutting speed of 60 m / s for a smaller thickness and 80 m / s for a larger thickness of circular saws. The corresponding revolutions for which the saw is calibrated are indicated on the saw blade.
routing: The amount of routing (one side) is usually 1/4 of the thickness of the disc body. Only the upper third of the tooth is divorced. The setting must be symmetrical, otherwise the circular saw will begin to deviate towards the larger setting. The wiring is always done before sharpening, after sharpening it is only controlled and corrected if necessary. If set too low, the saw blade overheats, loses strength and leads to the side. Excessively large set-up results in losses from too wide a cut, higher energy consumption and increased roughness of the cut surface.
For soft wood, choose a larger layout than for hard wood.
For slitting we choose a larger set than for cross-cutting.
For wet wood, choose a larger layout than for dry wood.
For a frozen tree, choose a smaller layout than for an unfrozen tree.
If the machine is in poor condition, we choose a large wiring.
What steel are circular saws made of?
The most common reasons for short sharpening times are:
- Overheating of the cutting inserts: This is manifested by the discoloration of the tips of the cutting inserts due to overheating of the material during sharpening. Overheating can occur due to too much pressure (removal of a large amount of material) of the grinding wheel on the surface to be ground, due to the use of a grinding wheel that is too hard, too fine grain of the grinding wheel, improper tool attachment or intensive sharpening without cooling.
Quote: Originally written by homyak1:
No, we are talking about different saws. These saws are for cutting metal in a bag or a large profile. They have a rather soft carbon fiber. And the question of the grade of steel, in order to carry out the correct hardening. You can, of course, by typing, but this is not our method.
I was just talking about the saws used for sawing wood, without soldering, taken out of service after reaching a diameter of 800 mm, used on machines Kara, Limet, etc.
Quote: Originally written by homyak1:
. but damn a freebie, she doesn’t give rest.
Not only a freebie, I saw somewhere here a photo of a knife with zone hardening from 9xc, I liked it, but the imported ones, in theory, should be better.
quote: Originally written by emirT:
Cut off a piece, temper it, assuming that it is 9XC, test it if you like making knives and enjoy the freebie.
Apparently, you will have to do so, I just would like to avoid unnecessary gestures.
Quote: Originally posted by Vitaliy:
avoid unnecessary body movements.
Victory-tipped discs
I hope all questions will disappear by themselves.
С-0.04 Mn-0.196 Si-0.006 P-0.0092 S-0.0267 Cr-0.26 Ni-0.017 Cu-0.018
Ti-0.0007 V-0.0091 Mo-0.0013 W-0.001 Nb-0.0045 Al-0.0655 Co-0.0279
“Band saw for wood.
C-0.722 Mn-0.682 Si-0.211 P-0.0184 S-0.0025 Ni-0.14 Cr-0.261 Cu-0.02 Mo-0.0023 W-0.008 V-0.0031 Ti-0.0015 Nb-0.0047 Al-0.0069 Co-0.0015
When using circular saws, you can expect the following surprise:
Circular saw diameter 700 mm, thickness 3 mm.
C-0.501 Mn-0.402 Si-0.402 P-0.0333 S-0.0289 Ni-0.255 Cr-0.756 Cu-0.163 Mo-0.1653 W-0.04 V-0.2703 Ti-0.0022 Al- 0.0194
Another circular saw, diameter 600 mm, thickness 6 mm.
C-0.606 Mn-0.423 Si-0.268 P-0.02 S-0.0131 Ni-0.109 Cr-0.390 Cu-0.140 Mo-0.0107 W-0.003 V-0.0052 Ti-0.0103 Al-0, 0163
Old Soviet gang saws.
C-0.841 Mn-0.454 Si-0.245 P-0.0188 S-0.025 Ni-0.035 Cr-0.586 Cu-0.089 W-0.0025 V-0.2148 Ti-0.0017 Al-0.0164
Good old 9HF.”(from)
I just would like to avoid unnecessary body movements
[/ QUOTE]
If you want without unnecessary gestures, then you need to know the brand exactly.
Quote: Originally posted by Ily_a:
no, well, this is absolutely impossible, how can it be without unnecessary gestures? not interesting, and no pleasure from the result. )))
Quote: Originally posted by Vitaliy:
photo of a knife with zone hardening from 9xc
Quote: Originally posted by Vitaliy:
imported, in theory, should be better.
Quote: Originally written by chyuck:
They have a reputation as a company., Production discipline, but here these concepts have long been forgotten. In addition, imported 24tr, our 8tr, in spite of the fact, take import. Why7
Quote: Originally posted by Vitaliy:
They have a reputation as a company., Production discipline, but here these concepts have long been forgotten. In addition, imported 24tr, our 8tr, in spite of the fact, take import. Why7
I ask the guru for help. Tell me who knows what kind of steel Soviet circular saws were made for cross-cutting. I have one with a diameter of 50 cm. And how blades from it are in business. I’m new to the site, please do not kick in the search right away.
With a high probability 85xf. Quite a decent steel. I made a couple of knives from an industrial circular disc (Disc without soldering). A modern tipped disc can be made from full G.
Nothing to add
I don’t know the brand, but I tried to shackle it with y7. it turned out to be a good knife. good contrast. http://guns.allzip.org/topic/97/461298.html
I have one. 600 mm in diameter. It is marked 9ХМФ. Looked in reference books, used mainly for the circus. drank. They declare a hardness of 61, after making a knife I feel that it is less. The next blade will burn.
quote: I have one, 600 mm in diameter. It is marked 9ХМФ. Looked in reference books, used mainly for the circus. drank. They declare a hardness of 61, after making a knife I feel that it is less. The next blade will burn.
quote: and this is correct! Since hardening at 61 units (and the same on frame saws) only on the tooth using HDTV
Perhaps! But provided that the saw was not in operation, on the working saws, all the sides were burned, and if the foliage was sawed or a pine tree was cut, then this is welded on it. you can hardly remove the angle grinder!
[QUOTE] The originals of the posted would Hoopoe:
[B]
With a high probability 85hf.
[/ B]
[/ QUOTE]
Although it may be 30hgsa
Stainless Steel Bone Saws
Cutting width: 190 mm
Cut height: 245 mm
Ergonomics allows you to get both quality and performance with complete safety. MONOBLOCK CASE | 100% STAINLESS STEEL INCLUDING FLYWHEELS | HINGED SCREEN WIPERS | 100% TIGHTNESS SX200 and SX220 Bandsaw Fully.
Cutting width: 200 mm
Cut height: 230 mm
Ergonomics allows you to achieve both quality and performance with complete safety. MONOBLOCK CASE | 100% STAINLESS STEEL INCLUDING FLYWHEELS | HINGED SCREEN WIPERS | 100% TIGHTNESS SX200 and SX220 Bandsaw Fully.
Cutting width: 240 mm
Cut height: 300 mm
Ergonomics allows you to achieve both quality and performance with complete safety. MONOBLOCK CASE | 100% STAINLESS STEEL INCLUDING FLYWHEELS | HINGED SCREEN WIPERS | 100% AIR TIGHT FOLDING TABLE FOR EASY CLEANING Belt.
Cutting width: 412 mm
Cutting height: 400 mm
band saw blade 3370 x 16 mm HBI machine dimensions. 1057 x 1030 x 1970 mm Weight grid 295. 305 kg The K440RS is the largest RS-Line mowing line model and is equipped with a table made of cast bearings. Combined with optional.
Cut width: 187 mm
Cut height: 230 mm
SHORT FACTS band saw blade 1820 x 16 mm Dimensions of HBI machine. 519 x 619 x 995 mm Weight grid 75.77 kg Table model K220 is ideal for a small butcher shop next door or for a meat section in a supermarket.
Cutting width: 228 mm
Cut height: 255 mm
SHORT FACTS band saw blade 2170 x 16 mm HBI machine dimensions. 579 x 702 x 1629 mm Net weight 110.115 kg The smallest band saw in our range. K260. Despite the very small footprint, the worker.
Features of band saws for metal
Cutting steel or other types of metals involves the use of special equipment, special working blades. The main feature of the belt-type equipment used for working with metal from woodworking counterparts is the relatively low speed of the working blade and the equipment with high-power motors. All band machines for metal are divided into 4 classes. Both the scope of its use and the cost depend on the belonging of the model to a certain category. Consider the characteristics of the classes:
- first. Quite expensive equipment. Suitable for processing metals of various degrees of hardness: from aluminum to high-alloy steels. Products are distinguished by large sizes and weight. If the machine is intended to work with hard metals, then a cooling system with a special liquid is provided. Almost all equipment that belongs to the first class is automated;
- second. The functionality of these band saws is the same as that of the previous type of equipment, but in terms of accuracy they are somewhat inferior to it. There are automatic and semi-automatic devices. In the latter case, the workpieces are fed manually;
- the third is used in home workshops and in industries where the accuracy of the cut does not really matter. When compared with the first two classes, the performance of saws in this category is 1.5-2 times less;
- the fourth. household models of saws for metal, including tabletop modifications. Compared to industrial models, the resource of household saws is much lower. Therefore, the equipment of the fourth class is designed for occasional use in the home workshop.
When working on metal, tape blades with teeth (universal version) and electric spark blades (in industrial versions) are used.
Band saws for metal
- Items 1. 60 (total 93)
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- 93 650.00 UAH 79 500.00 UAH
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- 106 772.00 UAH
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- 138 880.00 UAH
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- 439 500.00 UAH 375 999.00 UAH
Band saws. what is this tool?
The purpose of the band saws is to cut various materials: wood, metal, plastic or foam. An annular closed saw blade that rotates quickly is used as a working tool. The band saw is made of carbon steel or hard alloys. In some models, blades of 2 metals (bimetallic) are used, as well as blades, on the teeth of which hard alloy solders are applied. The width of the working blade varies from 13 to 80 mm. If the cutting method is vertical, narrower (from 6 mm) blades can be used.
The scope of the tool is wide enough: home workshops, band machines, sawmills. With this device, you can make a cut of complex shape and varying degrees of accuracy, depending on the class of equipment. For example, it is possible to form a cut of a parabolic or elliptical shape. The band saw is also suitable for making straight and corner cuts on pipes or metal rods. The tool is also used in furniture production: both for the manufacture of miniature products and for cutting long thick boards.
How to choose the right band tool?
Since band saws are versatile tools that can work not only on metal, but also on other materials, the option to adjust the speed of the saw blade is desirable. This makes it possible not only to perform a work task with high quality, but also does not damage the equipment. Hard metals are cut at low speeds, while softer materials are cut at high speeds. The second parameter that you should pay attention to when buying is design features. The swivel jaws of the band saw tool allow for straight, angular and curved cuts. When buying a band saw, they also pay attention to the size of the blade teeth: the larger they are, the deeper the cut is.
Band saw steel grade for metal
There are the following types of materials from which Wikus band saws are made:
Let’s consider them in more detail.
Tool steel band saws
Such saws are mainly used for sawing simple materials: unalloyed steels with low tensile strength, for cutting composite materials, for friction sawing on special machines. They are most suitable for use in the repair shop environment.
The production program and scope of each of the canvases can be found at the link.
Bimetal Band Saw Blades
The base blade of such a band saw is made of elastic spring steel (analogue. 45HGNMFA). A high-speed steel (HSS) profile wire is welded to the base blade by electron beam welding, after which the sawtooth profile is milled.
After the subsequent heat treatment, the cutting edges of the saw teeth have a hardness of 67.5. 69 HRC, and also have the outstanding wear resistance and redness characteristic of high-speed steels. This makes it possible to successfully use bimetallic saws in processing up to 90% of steels and alloys used in industry.
Depending on the brand and composition of high-speed steel, bimetallic saws of almost all manufacturers are divided into 2 main types. M42 and M51.
For bimetallic band saws from Wikus:
Hardness of cutting edges of teeth 67.5-68.5 HRC.
This material is suitable for sawing all major steel grades with hardness up to 40-45 HRC.
This allows this tool to be used for cutting high-strength, stainless and heat-resistant steels, including workpieces with a large cross-section and hardness up to 45 HRC.
Cutting edge hardness 69 HRC.
The durability of such a band blade, as a rule, is 10-20% higher than that of saws with a cutting edge material made of M42.
In 2009, Wikus discontinued saws with M51 cutting edge material and introduced a new generation of high-tech material. X3000. This material occupies a special position because it is obtained from high-quality high-speed steel by powder metallurgy. This made it possible, in contrast to traditional high-speed steels (M42 and M51), to achieve the following advantages:
Get a fine-grained structure with a more even distribution of dispersed carbides.
2. Significantly increase the hardness (up to 69-70 HRC), wear resistance and heat resistance, while maintaining the technological plasticity of the material.
3. To increase the reliability of the tool due to a decrease in the likelihood of the formation of defects during cutting, such as burns, chips and microcracks.
4. Increase tool life up to 25-50%.
Sawing austenitic, stainless, acid-resistant and other exotic steels and alloys is no longer a big problem thanks to the combination of the new high-performance cutting edge material X3000 and the optimized geometry of the GIGANT and VECTOR bi-metal band saws.
The production program and scope of each of the canvases can be found at the link.
Carbide Band Saw Blades
This tool is recommended for high-performance cutting of exotic, difficult-to-cut, heat-resistant and stainless steels and alloys, titanium, nickel, etc. hardness up to 62 HRC. Specially ground tooth geometries with cutting edge hardness up to 1600-3800 HV make the Wikus carbide saw program suitable for the most demanding needs.
These saws are of two types:
The production program and scope of each of the canvases can be viewed at the link.
Diamond band saws
Since diamond is the hardest material in nature (hardness up to 9000 HV), it is able to cut almost any material, metal and alloy. These are aluminum with inclusions of solid particles, and hardened and chrome-plated shafts, hard alloys, ferrodo, tempered glass, marble, granite, quartz, graphite, etc.
Bandsaw equipment is one of the main components of metalworking production and the manufacture of metal structures, one of the fastest, most accurate and economical ways to cut a significant amount of rolled solid and variable cross-section. An important role in this is played by the characteristics of the band saw, its pitch, setting, durability, and other parameters.
The main types of band saws used in modern production are saws from carbon steel grades and bimetallic products, saws with a base made of ordinary steels with high resilience and cutting parts made of other grades of steels. hard or high-speed.
Description GOST R 53924-2010
GOST R 53924-2010 prepared by JSC “VNIIINSTRUMENT”, introduced by the Technical Committee for Standardization TK 95 “Tool”, approved and put into effect by the Order of the Federal Agency for Technical Regulation and Metrology dated November 12, 2010 N 399-st. GOST applies to endless band saws for cutting section and shaped rolled metal, castings, sheet material, pipes and other products made of ferrous and non-ferrous metals, as well as non-metallic materials on band saw machines.
GOST R 53924-2010 includes modified basic regulatory provisions of the following international standards:
– ISO 4875-1: 2006 “Band saw blades for metal. Dictionary” (ISO 4875-1: 2006 “Metal-cutting band saw blades. Part 1: Vocabulary”);
– ISO 4875-2: 2006 “Band saw blades for metal. Characteristics and dimensions” (ISO 4875-2: 2006 “Metal-cutting band saw blades. Part 2: Characteristics and dimensions”).
The following standards are used in this standard:
GOST 3882-74 Hard sintered alloys. Grades (ISO 513-75 “Solid tool materials for cutting. Designation of the main chip groups and application groups”, MOD).
GOST 5950-2000 Bars, strips and coils from tool alloy steel. General specifications.
GOST 19265-73 Bars and strips from high speed steel. Specifications.
Options for the manufacture of tape canvases:
blades made of tool alloy steel in accordance with GOST 5950;
2. bimetallic blades (cutting part material. high-speed steel according to GOST 19265);
3. blades made of tool alloy steel with teeth equipped with hard alloy in accordance with GOST 3882;
4. friction cutting blades (under the influence of frictional heating) made of steel resistant to fatigue.
Types of tooth setting:
Standard set: Transverse set of each tooth alternately right and left.
Note. does not apply to canvases intended for work on ferrous metals.
Figure. Setting two adjacent teeth through one undistributed.
Setting two adjacent teeth through one unset: Setting one tooth to the right, one to the left, one without setting.
Figure. Setting two adjacent teeth through one undistributed
Wavy set: Transverse set of groups of teeth with regular change of direction of the set to the right and left.
Figure. Wavy layout
Group setting: Transverse setting of several teeth alternately to the right and left, followed by one at least undisturbed.
Figure. Group wiring
The general setting of the teeth of band saws of all versions. at the discretion of the manufacturer.
The setting of the teeth on the sides of the blade should be equal.
Limit deviations of the wiring. ± 0.05 mm.
The straightness tolerance of the lateral sides of the web in the transverse direction over the entire width of the undivided part should be no more than 2 μm / mm.
The main dimensions of the canvases must correspond to those indicated in the table
The length of endless band saws is determined according to the type of machine used.
Main characteristics of band saws
Obtaining a high-quality cut and the duration of the product’s operation depend on the accuracy of the selection of parameters such as pitch, setting and tooth shape. An important characteristic of a saw band is the tooth pitch, which is the number of saw teeth per inch (TPI). The tooth pitch can be constant or variable. Constant is used when working with solid section workpieces in industrial volumes, variable provides minimal vibration and high cut cleanliness.
For products with a constant step, its value ranges from 1 to 32, with a variable step. 10/14. 0.75 / 1.25. Below are tables of recommended saw pitch sizes for cutting solid steel:
And the recommended step sizes for working with profile and pipes:
However, saw manufacturers often offer their own recommendations for working with solid workpieces, profiles and pipes. They should be guided by the selection of saws for solving certain problems.
The next important parameter is the angle of rotation or inclination of the tooth relative to the plane of the blade or, in a more simplified name, the setting. The free movement of the blade, vibration, noise, section of workpieces and the ability to work with thin materials depend on this. There are the following basic options for tilting the teeth:
- Standard is a left tilted tooth, followed by a right tilted tooth and a straight tooth. The most commonly used set-up for cutting workpieces of all steel grades.
- Variable. left, right and wiping teeth. Provides minimal noise and vibration, suitable for working with soft materials.
- Wave routing. for cutting thin-walled rolled products.
- Combined. for pipes, profiles with variable cross-section and packages.
The capabilities of the band saw blade for metal also depend on the shape of the tooth. There are the following basic forms:
- NORMAL (N) with 0 ° rake angle. Designed to work with high-carbon alloys, for thin sections and rolled products with variable cross-section.
- HOOK (H) with 10 ° rake angle. for thick-walled pipes and solid billets.
- RP with 16 ° rake angle. work with solid and extra hard solid workpieces.
- MASTER. angle 10 ° and 16 °, the presence of a ground chamfer located in the longitudinal direction.
Marking and designation of tape blades
An example of decoding from the marking applied to the tape fabric Honsberg BI / M42 S 20×0.9×2362 mm, 10 / 14TPI:
Honsberg. German manufacturer of tape saws;
BI / M42. material of the cutting part of the teeth is bimetal M42;
S. Spectra tooth profile with 0 ° rake angle;
20. web width in mm;
0.9. blade thickness in mm;
2362. long “endless”, ring-welded fabric in mm;
10/14. variable pitch of teeth, indicates that there will be 10 teeth on the first inch of the band, and 14 teeth on the second, which will subsequently alternate along the entire length every 2.54 centimeters (Inch = 2.54 cm);
TPI is an abbreviation for Teeth Per Inch, which translates to Teeth Per Inch.
Constant band tooth pitch. all teeth are the same and spaced at the same distance.
Variable tooth pitch of the band. “small” and “big” the teeth alternate every inch and it turns out that one inch has one constant pitch of the teeth, the second has another. Belt blades with a variable tooth pitch are most preferable when cutting metal, since they have a wider working range compared to a constant pitch, and also reduce vibration and noise of the band blade.
The difference between the tape blades M42 and M51.
The cutting edge of the M51 blade is slightly harder than that of the M42 blade, but also more fragile. Due to its fragility, it makes sense to use M51 blades when cutting solid workpieces that are not prone to vibrations, for example, it is perfect for sawing stainless steel round timber, which will not be able to cut the M42 blade. The durability of the M51 band blade is usually 10-20% higher than that of saws with M42 cutting edge material. Another important point, M51 blades cannot be less than 27 mm wide, and the finest tooth pitch will be 4/6 TPI (the first inch is 4 teeth, the second inch is 6 teeth). For comparison, for M42 belt blades and 27 mm wide, the finest tooth pitch can be 14 TPI (14 pieces per inch).
Types of band saws
All modern blades for a band saw machine for metal, depending on the material, can be conditionally divided into three main categories:
- Saw blades made of carbon tool steel grades. A widely used type of band saws for economical cutting of many grades of steel, both unalloyed and alloyed. The tensile strength of this type of saws reaches 80 kPa / mm2.
- Bimetallic blades for a band saw machine for metal with a working part made of high-speed steel. have higher operating rates than products made of a homogeneous material. The most commonly used high-speed steel grade M42 (11P2M10K8) with additions of cobalt and molybdenum providing hardness up to 950 HV and red hardness. The tooth is connected to the spring part of the saw by electron beam welding.
- Carbide tooth bimetal saws. They are used under severe cutting conditions, for working with cast iron and other particularly hard materials. Used for cutting solid workpieces with a diameter of over 60 mm.
Benefits of sawing with band saws
Sawing technology on band saws is increasingly in demand in modern industries. The main advantages of using tape canvases include:
- the smallest amount of chips and waste from cutting;
- high precision manufacturing of the ends of parts;
- perfectly flat cut surface of the part;
- excellent performance and speed of the equipment;
- low noise and no vibration.
Cutting HUGE Steel Pipe with our Heavy Duty Bandsaw
By using band saw blades instead of the basic cutting methods with discs and knives, in the end we get the opportunity to save money. Metal is consumed more prudently, the degree of production waste generation is significantly reduced. In addition, the quality of the manufactured products significantly exceeds the analogs of disk or cutting on a hacksaw machine.
Cutting modes and durability
A high-quality cut and the duration of the saw operation also depend on the optimal selection of the cutting mode. speed and feed. The mode depends on the material of the workpiece, its size and profile. The speed is adjusted according to manufacturers’ tables and on the basis of practical indicators of chip type and thickness. With thin, the feed increases or decreases the speed, with thick chips or blue tint, the feed speed decreases or the cutting speed increases. The best option is slightly curling shavings.
As for the durability of saws, it depends on the resistance of the material to wear and many other factors, including resistance to cyclic alternating loads and correct operation. As a rule, the canvases of the leading manufacturers are designed for 140. 160 hours of operation. This indicator can be increased by removing the canvases for relaxation and, of course, by the correct selection of cutting parameters.
Bimetal. the cutting part of the blade, which is laser-soldered to the base made of spring steel, is a complex alloy of several metals obtained in various ways. Bimetal HSS M42 (analogue of 10P2M10K8) and HSS M51 (analogue of 12P10M4K10) can be manufactured by the method of mutual simultaneous casting, synchronous pressing or electroplating. In the case of band saws for metal, different manufacturers use excellent methods for their manufacture, the quality of the blade, its strength and service life depend on this.
Band saw steel grade for metal
There are the following types of materials from which Wikus band saws are made:
Let’s consider them in more detail.
Tool steel band saws
These band saws are manufactured from a solid strip of high quality alloy and hardened carbon tool steel. A hardened cutting edge and an extremely flexible backing strip guarantee the high quality of these blades. The hardness of the cutting edges of the teeth reaches 65-67 HRC.
Such saws are mainly used for sawing simple materials: unalloyed steels with low tensile strength, for cutting composite materials, for friction sawing on special machines. They are most suitable for use in the repair shop environment.
The production program and scope of each of the canvases can be viewed at the link.
Bimetal Band Saw Blades
The base blade of such a band saw is made of elastic spring steel (analogue. 45HGNMFA). A high-speed steel (HSS) profile wire is welded to the base blade by electron beam welding, after which the sawtooth profile is milled.
After the subsequent heat treatment, the cutting edges of the saw teeth have a hardness of 67.5. 69 HRC, and also have the outstanding wear resistance and redness characteristic of high-speed steels. This makes it possible to successfully use bimetallic saws in processing up to 90% of steels and alloys used in industry.
Depending on the brand and composition of high-speed steel, bimetallic saws of almost all manufacturers are divided into 2 main types. M42 and M51.
For bimetallic band saws from Wikus:
Hardness of cutting edges of teeth 67.5-68.5 HRC.
This material is suitable for sawing all major steel grades with hardness up to 40-45 HRC.
This allows this tool to be used for cutting high-strength, stainless and heat-resistant steels, including workpieces with a large cross-section and hardness up to 45 HRC.
Cutting edge hardness 69 HRC.
The durability of such a band blade, as a rule, is 10-20% higher than that of saws with a cutting edge material made of M42.
In 2009, Wikus discontinued saws with M51 cutting edge material and introduced a new generation of high-tech material. X3000. This material occupies a special position because it is obtained from high-quality high-speed steel by powder metallurgy. This made it possible, in contrast to traditional high-speed steels (M42 and M51), to achieve the following advantages:
Get a fine-grained structure with a more even distribution of dispersed carbides.
2. Significantly increase the hardness (up to 69-70 HRC), wear resistance and heat resistance, while maintaining the technological plasticity of the material.
3. To increase the reliability of the tool due to a decrease in the likelihood of the formation of defects during cutting, such as burns, chips and microcracks.
4. Increase tool life up to 25-50%.
Sawing austenitic, stainless, acid-resistant and other exotic steels and alloys is no longer a big problem thanks to the combination of the new high-performance cutting edge material X3000 and the optimized geometry of the GIGANT and VECTOR bi-metal band saws.
The production program and scope of each of the canvases can be viewed at the link.
Carbide Band Saw Blades
This tool is recommended for high-performance cutting of exotic, difficult-to-cut, heat-resistant and stainless steels and alloys, titanium, nickel, etc. hardness up to 62 HRC. Specially ground tooth geometries with cutting edge hardness up to 1600-3800 HV make the Wikus carbide saw program suitable for the most demanding needs.
These saws are of two types:
The production program and scope of each of the canvases can be viewed at the link.
Diamond band saws
Since diamond is the hardest material in nature (hardness up to 9000 HV), it is able to cut almost any material, metal and alloy. These are aluminum with inclusions of solid particles, and hardened and chrome-plated shafts, hard alloys, ferrodo, tempered glass, marble, granite, quartz, graphite, etc.
Bandsaw equipment is one of the main components of metalworking production and the manufacture of metal structures, one of the fastest, most accurate and economical ways to cut a significant amount of rolled solid and variable cross-section. An important role in this is played by the characteristics of the band saw, its pitch, setting, durability, and other parameters.
The main types of band saws used in modern production are saws from carbon steel grades and bimetallic products, saws with a base made of ordinary steels with high resilience and cutting parts made of other grades of steels. hard or high-speed.
Recommendations for the operation of tape blades
Preparation for work. running in the band:
A very important point, since the resource of the tape blade mainly depends on the controlled procedure of its “running in”. A sharpened pencil will break immediately, unlike a sharp, but slightly dull, the same principle when preparing a canvas. First, you need to let the blade run in to the machine pulleys, driving it idle through the air for about five minutes. Then, at a lower blade rotation speed, about 70% of the recommended and 50% of the recommended feed speed, cut the workpieces for about fifteen minutes, and only then bring the speed of rotation and feed to normal.
2. Blade tension:
The degree of tension of the band is indicated in the operating instructions for the machine. Professional and industrial models of bandsaw machines are equipped with built-in strain gauges, with which you can control the degree of tension. It is important not to overtighten the web, since due to the constriction, the durability is significantly reduced, which leads to the rupture of the tape web along the weld or the resulting cracks. If the blade is not tensioned enough, there will be a deviation from the perpendicular cutting plane and a twisted cut.
3. Operation of the blade:
The main indicator of the correct choice of cutting conditions is the absence of strong vibrations during cutting and the type of chips. Optimum cutting requires each tooth of the band to cut a certain chip thickness. In practice, the feed is selected according to the recommendations of the equipment manufacturers or according to the type of chips that are obtained during cutting. For thin or dusty chips, increase the blade feed speed or decrease the cutting speed. Lightly curling chips indicate the correct cutting mode. Thick or blue chips indicate excessive feed rate or less than necessary cutting speed. It is also important not to overheat the cutting material of the blade, hence it follows that intensive watering of the blade with coolant, the cutting zone and the workpiece being sawn is required. Reduce the feed if vibrations occur. Monitor the quality of the cut surface, seizure marks and cavities may be the result of incorrect selection of the pitch, processing modes or blade wear.
4. Rest of the canvas:
Resting the blade allows you to redistribute the fatigue stresses arising in the process of work, preserve the properties of the tool material and increase the service life. When working intensively throughout the working day, it is better to work with two canvases, one before lunch, the other after. At the end of the working day, it is imperative to loosen the tension of the blade, and even better, remove the blade from the machine, and, turning it inside out, hang it on a hook.
5. Approximate resource of tape blades:
The durability of the band depends on many factors, including:
– type of machine;
– operating modes;
– processed material;
– cross section of the material;
– canvas material;
– preparation of the canvas;
– observance of operating rules;
– finally, the mood of the worker.
On average, with a correctly selected tooth pitch, the resource of one running meter of the blade is enough to cut 1.5-2.5 m² of solid ferrous metal.
For sawing thin-walled workpieces, such as pipes, sheet metal and the like, belt blades with a fine tooth pitch are required, otherwise there is a risk of damaging or breaking the tooth of the bimetallic blade.
Large workpieces should be cut with coarse-pitch band blades. Coarse pitch increases productivity and leaves plenty of room for free chip formation.
Sawing soft and tough materials such as aluminum and bronze requires a lot of free space for the formation of chips, they also use large-toothed blades here, as they prevent the chips from accumulating and getting stuck between the teeth.
Main characteristics of band saws
Obtaining a high-quality cut and the duration of the product’s operation depend on the accuracy of the selection of parameters such as pitch, setting and tooth shape. An important characteristic of a saw band is the tooth pitch, which is the number of saw teeth per inch (TPI). The tooth pitch can be constant or variable. Constant is used when working with solid section workpieces in industrial volumes, variable provides minimal vibration and high cut cleanliness.
For products with a constant step, its value ranges from 1 to 32, with a variable step. 10/14. 0.75 / 1.25. Below are tables of recommended saw pitch sizes for cutting solid steel:
And the recommended step sizes for working with profile and pipes:
However, saw manufacturers often offer their own recommendations for working with solid workpieces, profiles and pipes. They should be guided by the selection of saws for solving certain problems.
The next important parameter is the angle of rotation or inclination of the tooth relative to the plane of the blade or, in a more simplified name, the setting. The free movement of the blade, vibration, noise, section of workpieces and the ability to work with thin materials depend on this. There are the following basic options for tilting the teeth:
- Standard is a left tilted tooth, followed by a right tilted tooth and a straight tooth. The most commonly used set-up for cutting workpieces of all steel grades.
- Variable. left, right and wiping teeth. Provides minimal noise and vibration, suitable for working with soft materials.
- Wave routing. for cutting thin-walled rolled products.
- Combined. for pipes, profiles with variable cross-section and packages.
The capabilities of the band saw blade for metal also depend on the shape of the tooth. There are the following basic forms:
- NORMAL (N) with 0 ° rake angle. Designed to work with high-carbon alloys, for thin sections and rolled products with variable cross-section.
- HOOK (H) with 10 ° rake angle. for thick-walled pipes and solid billets.
- RP with 16 ° rake angle. work with solid and extra hard solid workpieces.
- MASTER. angle 10 ° and 16 °, the presence of a ground chamfer located in the longitudinal direction.
Types of band saws
All modern blades for a band saw machine for metal, depending on the material, can be conditionally divided into three main categories:
- Saw blades made of carbon tool steel grades. A widely used type of band saws for economical cutting of many grades of steel, both unalloyed and alloyed. The tensile strength of this type of saws reaches 80 kPa / mm2.
- Bimetallic blades for a band saw machine for metal with a working part made of high-speed steel. have higher operating rates than products made of a homogeneous material. The most commonly used high-speed steel grade M42 (11P2M10K8) with additions of cobalt and molybdenum providing hardness up to 950 HV and red hardness. The tooth is connected to the spring part of the saw by electron beam welding.
- Carbide tooth bimetal saws. They are used under severe cutting conditions, for working with cast iron and other particularly hard materials. Used for cutting solid workpieces with a diameter of over 60 mm.
Marking and designation of tape blades
An example of decoding from the marking applied to the tape fabric Honsberg BI / M42 S 20×0.9×2362 mm, 10 / 14TPI:
Honsberg. German manufacturer of tape saws;
BI / M42. material of the cutting part of the teeth is bimetal M42;
S. Spectra tooth profile with 0 ° rake angle;
20. web width in mm;
0.9. blade thickness in mm;
2362. long “endless”, ring-welded fabric in mm;
10/14. variable pitch of teeth, indicates that there will be 10 teeth on the first inch of the band, and 14 teeth on the second, which will subsequently alternate along the entire length every 2.54 centimeters (Inch = 2.54 cm);
TPI is an abbreviation for Teeth Per Inch, which translates to Teeth Per Inch.
Constant band tooth pitch. all teeth are the same and spaced at the same distance.
Variable tooth pitch of the band. “small” and “big” the teeth alternate every inch and it turns out that one inch has one constant pitch of the teeth, the second has another. Belt blades with a variable tooth pitch are most preferable when cutting metal, since they have a wider working range compared to a constant pitch, and also reduce vibration and noise of the band blade.
The difference between the tape blades M42 and M51.
The cutting edge of the M51 blade is slightly harder than that of the M42 blade, but also more fragile. Due to its fragility, it makes sense to use M51 blades when cutting solid workpieces that are not prone to vibrations, for example, it is perfect for sawing stainless steel round timber, which will not be able to cut the M42 blade. The durability of the M51 band blade is usually 10-20% higher than that of saws with M42 cutting edge material. Another important point, M51 blades cannot be less than 27 mm wide, and the finest tooth pitch will be 4/6 TPI (the first inch is 4 teeth, the second inch is 6 teeth). For comparison, for M42 belt blades and 27 mm wide, the finest tooth pitch can be 14 TPI (14 pieces per inch).
Description GOST R 53924-2010
GOST R 53924-2010 prepared by JSC “VNIIINSTRUMENT”, introduced by the Technical Committee for Standardization TK 95 “Tool”, approved and put into effect by the Order of the Federal Agency for Technical Regulation and Metrology dated November 12, 2010 N 399-st. GOST applies to endless band saws for cutting section and shaped rolled metal, castings, sheet material, pipes and other products made of ferrous and non-ferrous metals, as well as non-metallic materials on band saw machines.
GOST R 53924-2010 includes modified basic regulatory provisions of the following international standards:
– ISO 4875-1: 2006 “Band saw blades for metal. Dictionary” (ISO 4875-1: 2006 “Metal-cutting band saw blades. Part 1: Vocabulary”);
– ISO 4875-2: 2006 “Band saw blades for metal. Characteristics and dimensions” (ISO 4875-2: 2006 “Metal-cutting band saw blades. Part 2: Characteristics and dimensions”).
The following standards are used in this standard:
GOST 3882-74 Hard sintered alloys. Grades (ISO 513-75 “Solid tool materials for cutting. Designation of the main chip groups and application groups”, MOD).
GOST 5950-2000 Bars, strips and coils from tool alloy steel. General specifications.
GOST 19265-73 Bars and strips from high speed steel. Specifications.
Options for the manufacture of tape canvases:
blades made of tool alloy steel in accordance with GOST 5950;
2. bimetallic blades (cutting part material. high-speed steel according to GOST 19265);
3. blades made of tool alloy steel with teeth equipped with hard alloy in accordance with GOST 3882;
4. friction cutting blades (under the influence of frictional heating) made of steel resistant to fatigue.
Types of tooth setting:
Standard set: Transverse set of each tooth alternately right and left.
Note. does not apply to canvases intended for work on ferrous metals.
Figure. Setting two adjacent teeth through one undistributed.
Setting two adjacent teeth through one unset: Setting one tooth to the right, one to the left, one without setting.
Figure. Setting two adjacent teeth through one undistributed
Wavy set: Transverse set of groups of teeth with regular change of direction of the set to the right and left.
Figure. Wavy layout
Group setting: Transverse setting of several teeth alternately to the right and left, followed by one at least undisturbed.
Figure. Group wiring
The general setting of the teeth of band saws of all versions. at the discretion of the manufacturer.
The setting of the teeth on the sides of the blade should be equal.
Limit deviations of the wiring. ± 0.05 mm.
The straightness tolerance of the lateral sides of the web in the transverse direction over the entire width of the undivided part should be no more than 2 μm / mm.
The main dimensions of the canvases must correspond to those indicated in the table
The length of endless band saws is determined according to the type of machine used.
Cutting modes and durability
A high-quality cut and the duration of the saw operation also depend on the optimal selection of the cutting mode. speed and feed. The mode depends on the material of the workpiece, its size and profile. The speed is adjusted according to manufacturers’ tables and on the basis of practical indicators of chip type and thickness. With thin, the feed increases or decreases the speed, with thick chips or blue tint, the feed speed decreases or the cutting speed increases. The best option is slightly curling shavings.
As for the durability of saws, it depends on the resistance of the material to wear and many other factors, including resistance to cyclic alternating loads and correct operation. As a rule, the canvases of the leading manufacturers are designed for 140. 160 hours of operation. This indicator can be increased by removing the canvases for relaxation and, of course, by the correct selection of cutting parameters.
Bimetal. the cutting part of the blade, which is laser-soldered to the base made of spring steel, is a complex alloy of several metals obtained in various ways. Bimetal HSS M42 (analogue of 10P2M10K8) and HSS M51 (analogue of 12P10M4K10) can be manufactured by the method of mutual simultaneous casting, synchronous pressing or electroplating. In the case of band saws for metal, different manufacturers use excellent methods for their manufacture, the quality of the blade, its strength and service life depend on this.
Homemade band saw
The working table of a homemade band saw (dimensions 420×720 mm) is made of plywood 20 mm thick, pasted over with textolite on top. It is edged around the perimeter with hardwood slats. The table has narrow grooves for guiding the sawing band. Base. box measuring 420x720x500 mm, glued from 20 mm plywood. Among other things, it serves as a place for collecting sawdust.
Carrying bar. section of channel No. 8 680 mm long, the shelves of which are cut to a height of 20 mm for convenience. The bar is attached to the table using a 40×40 mm angle bracket and four M8 bolts. The saw belt drive pulleys are machined from 20 mm thick plywood. On the working surface, they are pasted over with dense sheet rubber, docked on a mustache. Used polyurethane adhesive. After rubberizing the pulleys, the wood is impregnated with epoxy resin, sanded and painted. The working surface is given the barrel shape necessary to hold the running saw band. A bushing made of duralumin is glued into the upper pulley with epoxy resin, in which a seat for a ball bearing 60203 is machined. The lower pulley is mounted on an axle made of steel of the 30HGSA type and is fastened with three 5×20 screws. The axle is inserted into a 60203 double-ball bearing axle box mounted on the lower end of the carrier bar. At the other end of the axle, the driven pulley of the belt drive is fixed through a spacer sleeve. After installation, the belt pulleys are balanced. The principle of operation and the dimensions of the parts of the saw belt tension system are clear from the figures shown (section A-A).
The gear ratio of the belt drive from the engine is i = 1, therefore the driving and driven pulleys are the same, with the exception of the bore, which on the driving pulley depends on the engine shaft. The pulleys are made of duralumin. V-belt. A710 (in this design).
To eliminate the vibrations of the sawing band, a damper (vibration damper) is provided, assembled from textolite parts on M6 bolts. The fixed element of the damper is fixed at the bottom of the working table, and the movable bar allows you to select the required clearance. It should be noted that an upper damper is also provided on the band saw, but its installation is advisable if the upper pulley of the sawing band starts “hit the diameter”. Otherwise, the upper damper only increases the friction of the belt. By design, it is similar to the main one and, if necessary, is attached to the rod with M5 bolts using a special bracket 105 mm above the plane of the desktop.
The guide for feeding the sawn timber is made of steel angle 100×100 mm. It is advisable to grind its perpendicular planes on a machine. In one of the shelves, two grooves are made along the edges to adjust the gap between the guide and. tape, and in the middle. cutout to increase the stroke of the plank. Safety during work is ensured by a protective casing that covers the entire upper pulley assembly of the saw band, which comes out of the casing cavity only in the working area.
The band saw blade itself deserves a lot of attention. It should be flexible enough on the one hand and strong. with another. For its production, we recommend cold-rolled sheet steel grade U8, U10 or 65G with a thickness of 0.2-0.4 mm for sawing soft wood (balsa, linden) or 0.4-0.8 mm. for harder rocks. By the way, many people use steel tape measures made of high-quality metal with a thickness of 0.2 mm and a width of about 10 mm for this purpose. “Automatic” modern curved tape measures are not suitable. only old samples are suitable. The length of the workpiece for the given dimensions of the machine. 1600-1700 mm. On the strip-blank, the teeth are cut with a file with a pitch of about 3 mm, after which the strip is soldered into a ring, the ends are sharpened in thickness on a mustache over a length of 3-6 mm. Then the place of the adhesion is sprinkled with brown and warmed up on a gas burner. Solder of the PSR-40 brand is applied to the joint and the seam is tightly compressed with pliers with asbestos pads on the sponges (otherwise the joint cools down quickly and the metal in this area becomes brittle). If necessary, the joint is ground. To obtain a better cutting surface, the front and rear surfaces of the teeth are sharpened in the same way as a hacksaw for wood and are slightly parted. Of course, you can also use commercially available blades for branded band saws, but then the dimensions of the machine should be made in advance in accordance with the dimensions of the purchased blade.
The considered homemade band saw is used for straight-line sawing of soft woods (balsa, linden, aspen, spruce, pine). It is possible to cut even harder species (beech, oak, mahogany) with a 0.8 mm thick tape installed on the machine.
The disadvantage of this version of a homemade band saw. small overhang of the canvas, however, this greatly simplifies the design. If the small overhang of the blade does not suit you, then so that the overhang of the blade is like that of branded band saws, you will have to make the arrangement of the bearing bar like theirs and use pulleys of a larger diameter.
Technical characteristics of a homemade band saw:
Maximum cutting thickness, mm
soft rocks. up to 100
hard rocks. up to 40
The smallest cutting width, mm. 0.25
Belt drive pulley diameter, mm. 240
Center distance of belt drive pulleys, mm. up to 500
Gear ratio from engine to drive pulley, i. one
Engine speed, rpm 2800
Electric motor power, kW. 0.6
Rated voltage, V. 380
Linear speed of the belt, m / s. 35
Belt length, mm. 1600-1700
Sawing speed, m / min. up to 5
Overall dimensions, mm. 720x420x920
Other drawings for making a homemade band saw:
Jet HVBS-712K 414459T
Unlike the above-described machine for metal, this semi-professional one works from a power supply of 380 V. It has a hydraulic feed system and an automatic cut-off switch. Thanks to the powerful motor, this machine can withstand heavy loads and is able to work for a long time. Quick-clamping and firmly holding vise rotates up to 45 degrees. The set includes a wire brush for cleaning the workplace from shavings.
Technical specifications
A standard band saw consists of:
- Durable case.
- Powerful engine.
- Sharp toothed blades.
- Fixed jaw vise.
- Saw tension screw.
- Mechanism loading and feeding material for processing.
- Control panels.
Band saws for metal from saws for wood are distinguished by a slow blade speed and more powerful motors that can withstand heavy loads.
To get an even cut, carefully select the cutting blade. It looks like a flexible strip with sharp teeth, it is worn on two drums, one of which is connected to an electric motor.
The canvases are made from a variety of metals, but carbon steel is recommended. Most often used bimetallic band saws, cutting even nickel and titanium based alloys.
PROMA PPS-170H 25017000
Differs in excellent performance and ease of operation, gives an excellent quality of work in metal. Equipped with an emergency button that turns off a powerful three-phase motor in case of malfunction. Has a simple saw band tension mechanism. It is chosen for serial and small-scale production.
Resilience and speed
The durability of the saw band depends on:
- Correct cutting mode.
- The qualities of the tape.
- Saw designs.
- Body material and shape.
- Quality of cutting fluid.
If the machine suddenly vibrates, then you need to change the feed rate in the right direction. The duller the teeth of the belt, the higher the feed should be.
Proma PPK-115 25330742
The metal saw has a rigid structure, high performance and three speed settings. The belt drive protects the motor from overload. Due to its light weight and parameters, it is easy to move around the room. During operation, it is almost silent and gives out a low level of vibration, which increases the level of comfort of work.
Jet MBS-56CS 50000320M
This model of band saw is considered reliable for medium-sized production, and produces cuts at three different speeds. The robust design minimizes vibration, allowing precise and accurate work. Replacing the belt is quick and easy, no additional tools required. The machine is equipped with automatic engine shut-off and hydraulic feed system. Transportation is carried out using the wheels of the machine.
Recommended cutting data
High speed is fraught with the fact that the machine can make a lot of noise and vibrate, and the blade from overloading at best becomes dull, at worst. bursts or deforms. Therefore, it is necessary to control the feed according to the chip shape:
- Thick, curly, elastic. perfect shavings. Feed rate and speed are matched correctly.
- Thick, hard, short or fragile. reduce saw speed and pace. Check coolant.
- Thick, hard, elastic and short. slightly reduce the feed rate, check the correct tooth pitch.
- Thick, hard, elastic and long. slightly increase feed rate, check blade teeth.
- Slim, straight, elastic. increase feed rate.
- Powdery. decrease saw speed and increase feed rate.
- Thin, tightly curled. reduce feed rate and use a coarser tooth pitch.