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all (18) optimizing tool life (11) maximizing uptime (10) choosing a sawing machine (5) FAQ (4) costs & benefits (4) other (2) automating a process (2) sawing different materials (2)
Posted by Christian Mayrhofer
Heavy material infeed systems in production sawing systems are often over-engineered in an attempt to avoid severe damage from dropped loads. The downfall? The potential for significant cost increases.
Posted by Willy Goellner
The carbide tips of a circular saw blade crack under extreme temperature changes, demonstrating why a flush coolant system won’t work on carbide cold saws.
Posted by Willy Goellner
Circular carbide saw machines and band saw machines both have their place on a shop floor. Your needs and overall goals will determine if a circular saw machine or a band saw machine is best for your operation.
Posted by Chris Rindels
Combination machines with material handling streamlines rail sawing and drilling processes -- providing more throughput, increased quality and efficiency, and improved viability.
Posted by Willy Goellner
Minimum Quantity Lubrication (MQL) is used in cold sawing to prevent heat build-up through friction reduction to keep both the material and the blade cool during the sawing process.
Posted by Willy Goellner
Circular cold saws allow both the material and blade to remain cool during the sawing process by transferring the generated heat to the chips.
Posted by Willy Goellner
Carbide-tipped circular saw blades are offered in three versions with different cost structures: Re-grindable (Resharpenable) Carbide-Tipped Saw Blades, One Way (Throwaway) Blades, and Replaceable Carbide Tip Circular Saw Blades.
Posted by Willy Goellner
When you have to cut a lot of alloy steel, cutting speed is an obvious issue - but are you getting the saw for a good price? We'll explain how shock load and operator error can affect the total cost of your carbide billet saw.
Posted by Willy Goellner
The heat from the cutting process, especially using negative cutting angles when cutting steel, transfers to the chip, causing it to expand and jam in the slot. This can be prevented by splitting the chip. There are two common tooth geometries developed to split the chip: “Triple Chip” and “Notch Grind.”
Posted by Christian Mayrhofer
Torsional vibrations are hard to measure because of the rotating elements (gears, shafts) that are inside a closed gear case and not easily accessible. However, knowing the exciting torque, passing through the gear train and the gear data, critical vibrations such as resonance can be calculated and analyzed. The calculations and theoretical analysis shown in this article show that much can be theoretically analyzed, where practical limitations exist.
Posted by Willy Goellner
There are several proven methods to minimize backlash and reduce vibration during the carbide sawing cycle. The most damaging aspect of the sawing process is the entering and exiting of the circular blade in and out of the material. The "hammering" effect at the beginning and ending of the saw process can severely damage the carbide teeth of the saw blade. Saw machine designers have created several devices of varying complexity and costs to minimize these problems.
Posted by Willy Goellner
Achieve the highest productivity in metal sawing by taking care of your carbide tips. Production managers and manufacturing engineers choose circular carbide saw systems when they need the sawing method with the highest productivity. Without a doubt, circular sawblades equipped with carbide teeth are the most productive tool for high production metal sawing, but if you are replacing your blades too often, high productivity will be negated by the high cost of tooling and the lengthy changeover time.
Posted by Willy Goellner
This third and final article in the current series describes how to best minimize the damaging effects of vibrations and resonance with stabilizers and dampers. Even with a well-designed carbide saw, blade vibrations still occur. That is because it is nearly impossible to take into account every possible cause of vibration. Understanding stabilizing and damping best practices is the key to minimizing the inevitable vibrations that occur during the sawing process.
Posted by Willy Goellner
In this second of three articles, we focus on the destructive force behind carbide saw breakdowns with an in-depth look at resonance. Do not let resonance destroy your sawing machine and ruin efficiency within your shop. Learn how to test resonance and prevent a catastrophic outcome.
Posted by Willy Goellner
Vibration is harmful in any sawing machine, but in high production saws with hard and brittle carbide-tipped blades, it can be catastrophic. Reducing vibration is the main focus for machine designers, because vibration dramatically affects the tool life of the saw blade and increases the overall cost-per-cut. This article – which is first of a three-part series – focuses on the damaging effect and prevention of vibration in carbide sawing.
Posted by Willy Goellner
Compliance is defined as the measure of the ability of a mechanical system to respond to an applied vibrating force, expressed as the reciprocal of the system stiffness. In short, it measures the weakness of the system. In a carbide saw, the most critical component subject to torsional and lateral vibration of the saw blade, is the gearbox, commonly called the head.
Posted by Willy Goellner
Torsional vibration in carbide saws has the most damaging effect on the tool life of carbide tipped circular saw blades. It is also influenced by the blade diameter, the quality of the saw blades, the spindle gear diameter, the compliance of the gear train in the saw head and feed system, and the stiffness of the fixture and machine structure.
Posted by Willy Goellner
The name carbide saw came from the tool, a circular saw blade, with silver soldered carbide tips. It competed with and just about replaced, solid or segmental HSS blades, because carbide is much harder than HSS. Before HSS saws were developed, abrasive, friction or hot saws were used and are still manufactured for certain applications. These processes create heat and are therefore called hot saws.