is, the more frequently the teeth engage the metal. A longer blade will
give you longer blade life and fewer
changeovers. You also reduce the
proportional expense of the weld
splice, as it’s better to amortize that
cost over a longer blade than a shorter blade.
5. What are my overall costs?
No manufacturing process is an island (see Figure 4).
Procedures throughout the organization can influence
band sawing productivity. For instance, say your company
stocks a certain material that needs to be annealed before
it can be cut on the band saw. So you send it out to be
and annealing the material? Opportunity costs play into
this equation too. Does sending parts out for annealing
cause orders to be late? Do customer relationships suffer?
Indeed, these considerations apply not just to band sawing
but to any situation. In manufacturing—and, really, in any
business—it always pays to look at the big picture.
gyromeus2005.qxp 11-05-2005 13:20 Side 1
Regarding the blade splice, note
that the flash-welding process that
forms the blade into a loop doesn’t
involve alloying. The process doesn’t
use filler metal, so counter to common belief, the joint is not inherently stronger than the base material.
That’s why if a blade does snap prematurely from improper operation
or maintenance, it’s likely to be along
the weld joint.
You could cut this material in its natural state, but your
band saw expenses would double. But does this extra cost
in band sawing outweigh the money spent transporting
Dale Petts is the global product manager, metal products,
at Simonds International, 135 Intervale Road, Fitchburg,
MA 01420, 978-424-0100, www.simondsint.com.
Images courtesy of Simonds International.
Flexible, effective, fast
Automatic, oscillating deburring system
Related to this is basic preventive
maintenance. As a cutting tool, the
band saw is somewhat unusual because it isn’t locked down in place.
It moves, so it relies on rollers or carbide pads to keep aligned, and these
are subject to wear.
for stainless, aluminum and other materials.
Deburring of punched,
laser cut and
•No critical heating
of the surface
of protective foil.
As shown in this online cost calculator,
myriad variables go into determining
the true costs behind a sawing operation.
(Source: Simonds International, www.
damage to the
Monitor the alignment of the
wheels holding the band saw blade.
Those wheels have bearings that
wear over time, causing the wheels to
misalign to a point that the blade can
begin to rub against the flange of the
wheel. This creates burrs and causes
severe work hardening on the blade’s
back edge. When this happens, the
blade snaps prematurely.
pieces is possible.
Finally, don’t forget the cutting
fluid. Once the saw tip enters the
workpiece, there’s very little opportunity for the fluid to remain on the
tip. That’s why band sawing usually
requires a rich fluid concentration,
with more lubricant for maximum
adhesion. The better the fluid adheres to the tip during the operation,
the more consistent your cutting will
be, and the longer your blade will last.
Dry, Oscillating Deburring Technique
Hansen & Hundebol Inc.
3402 Oakcliff Road
Phone: (770) 452-1271
Suite B- 7
Fax: (770) 452-7090
Atlanta GA 30340