Band saw for metal. "Bulgarian" for serious work! Band saw blades Band saw blades

At present, 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 only work with trusted suppliers: Simonds, Lenox and DoAll. Confidence in the quality of the supplied products allows us to provide a lifetime weld guarantee.

American tape canvases Simonds, Lenox and DoAll are considered to be among the best. They are used for sawing on sawmills, vertical, horizontal and band-slitting machines. The tape blade of these manufacturers provides an even and accurate cut in materials made of wood, plastic and metal.

You can buy a band saw blade from us, as well as band saws welded into a ring for both wood and metal at the best price!

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

With a large amount of use of lumber, sooner or later the question of own sawmill arises. Similar installations are commercially available, but their cost is excessively high.

Therefore, many home craftsmen make their own sawing machine. The following options are used:

Homemade band saw - how to make a sawmill

The main problem of such an installation is its dimensions. Owners of apartments with balconies need not worry. This device is not for you. Unless the desktop version is a substitute for a manual jigsaw.

If we are talking about dissolving round timber into logs, you need a spacious shed, a barn or a separate workshop. Of course, all this is located in the courtyard of a private house.

IMPORTANT! Considering potential danger designs, and dimensions of blanks - the room is selected taking into account the free space around the sawmill.

Drawings are best made using specialized programs, for example, AutoCAD. General form structures in a three-dimensional image is shown in the illustration:

This material describes the vertical tape.

Frame manufacturing

The most important part of the machine is the frame, or bed. It bears the entire weight of the structure and is a support for the desktop. You can make it from a steel profile or a corner, but in terms of material cost, wood is preferable.

The sawmill can be for wood or metal, depending on the selected canvas. At the same time, a properly manufactured frame will ensure reliable operation with any material.

It is undesirable to build a frame from plywood or chipboard. best material there will be a 20 mm board, from which any configuration of the bed can be assembled. The design is glued according to the principle - each next layer crosses the previous one with the direction of the fibers.

It is possible to strengthen the structure by using self-tapping screws to fasten the layers, however, glue remains the main binding material. The “C” shaped structure is rigid, and at the same time relatively elastic. That is, the frame, in addition to the bearing component, acts as a kind of damper, which allows you to smooth out the jerks of the blade for the band saw.

Top pulley block

The next critical part of the installation is the adjustable block of the upper wheel (pulley). The shaft must move vertically to provide tension to the web when it inevitably stretches during operation. The frame is made of durable wood (beech or oak).

Inside the frame is a wooden insert made of the same wood, in which the shaft for the wheel is directly attached. The shaft is machined according to the inner diameter of the wheel bearing.
The insert with the shaft must have one degree of freedom to adjust the axis inclination.

This will be required when adjusting the belt tension. The inclination is adjusted with a threaded stud and a set of nuts integrated into the wood.

Vertical movement is carried out by means of a screw mechanism with a hexagonal head. You can tighten the block with a socket wrench, or install a stationary handle for adjustment. The block frame itself moves along the guides installed in the upper part of the bed.

To do this, they are pre-milled grooves corresponding to the racks of the frame.

IMPORTANT! All nuts in the adjusting mechanism are reinforced with metal plates. Nuts can be welded on if necessary.

The shaft is machined with a flange, with which it is fixed from the back on a wooden insert. An example of such a flange in the illustration:

Manufacturing of wheels (pulleys)

Material for gluing wheels - plywood circles. Cut with a milling compass. Depending on the thickness of the material, there can be 2 or 3 layers. The total thickness of the wheels is about 30 mm. After gluing, it is necessary to cut a hole for the bearing.

For structural stability, it is better to fix the bearing in a coupling machined from fluoroplast or textolite. You can get by with aluminum if you find a circle of suitable diameter.
From the side of the block, a fluoroplastic washer is put on the shaft.

It is undesirable to use metal, due to accelerated wear. The outer side of the bearing is fixed by a flange, in the illustration it is square.

The running surface of the wheels is turned to a barrel shape. In this case band-saw self-centering. A bicycle camera is put on and glued to the finished surface. After the final assembly, the wheels are balanced. This can be done by changing the diameter of the holes that are drilled into the disc.

IMPORTANT! When installing the bearing, it is necessary to ensure that the shaft is perpendicular. In the event of a deviation (even a slight one), the wheel will have a beating on the plane, and the tape can come off.

A drive pulley is attached to the lower wheel. The shaft is installed rigidly, without the possibility of adjustment. It is better to adjust the tension of the drive belt by the position of the engine; for this, its foundation is equipped with longitudinal grooves at the points of attachment to the base of the machine.

The normal wheel speed for a band saw is 700-900 rpm. When calculating the diameters of the drive pulleys, it is necessary to take into account the operating speed of the electric motor.

The tabletop along with the base is also made of wood. The base is made in the form of a cabinet, inside which the engine with a starting device, and boxes for fixtures and spare parts will be hidden.

The table is made of thick plywood, textolite is glued on the working side. A good option may be a countertop from kitchen furniture with a durable laminate on the surface.
For convenience, the tabletop can be made swivel.

In this case, it will be possible to cut at the desired angle. It makes no sense to describe the mechanism for tilting the tabletop, since each master will decide for himself what degrees of freedom he will need.

Complete with a table, it is necessary to make a parallel stop. The design is the most diverse: from a profile with two clamps to a roller guide system.

Band saw setting

To begin with, the wheels are set strictly parallel to each other. The vertical displacement of the pulleys is removed with the help of fluoroplastic washers put on the shafts. The initial start is carried out without guides, and a test cut is made without load. Properly tuned wheels rotate without jerks, the belt does not tend to come off the pulleys.

After setting, the web guide block is installed. Without it, it is impossible to cut under load. Design feature - the module consists of two parts, but both halves must be set strictly along the line of the saw blade.

Band saw blades

There are craftsmen who make their own band saw blades. You can purchase a blank in the form of a steel strip, and sharpen the band saw according to the template. Connecting the web into a closed tape is the most difficult step in manufacturing. Welding of band saws is carried out by butt contact method. There should be no overlap.

After joining, the joint is polished.
However modern assortment canvases, allows you to buy a kit for any material according to affordable price.

So don't waste your time making Supplies- this is not the case when it makes sense to apply your skills.

Before buying, use the reference material on the selection of the width of the web, depending on the radius of curvature. Perhaps you will cut out curly wood products at your sawmill.

The video shows step by step how to do it. homemade saw on wood from plywood and a hub from a Zhiguli. After assembly, a 6TPI wood blade 3380 × 0.65x10 mm is used to work on the saw. from machine JWBS-18 Jet PW10.3380.6. In general, the saw blade must be selected according to the tooth profile, depending on the type of wood. For example: hardwoods are sawn with a tape with a width of 80 mm or more.

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 saw blades are manufactured from a single piece of high quality alloy and hardened carbon tool steel. The hardened cutting edge and the highly flexible backing belt 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 limit strength, for cutting composite materials, for friction sawing on special machines. They are most suitable for use in repair shops.

Bimetal Band Saws

The base blade of such a band saw is made of elastic spring steel (analogue - 45KhGNMFA). A profiled wire made of high speed steel(HSS), after which the profile of the saw teeth is milled.

After subsequent heat treatment, the cutting edges of the saw teeth have a hardness of 67.5 - 69 HRC, and also have outstanding wear resistance and red hardness, characteristic of high speed steels. This allows you to successfully use bi-metal saws in the processing of 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 Wikus bimetal band saws:

In 2009, Wikus phased out saw blades with M51 cutting edges and introduced a new generation of high-tech material - X3000. This material occupies a special position, since 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:

1. Get a fine-grained structure with a more uniform distribution of dispersed carbides.
2. Significantly increase hardness (up to 69-70 HRC), wear resistance and heat resistance while maintaining the technological plasticity of the material.
3. Increase the reliability of the tool due to a decrease in the likelihood 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 X3000 high-performance cutting edge material and the optimized geometry of the GIGANT and VECTOR bi-metal band saws.

production program and the scope of each of the canvases can be viewed at the link.

Carbide Band Saws

This tool is recommended for high-performance sawing of exotic, hard-to-cut, heat-resistant and stainless steels and alloys, titanium, nickel, etc. hardness up to 62 HRC. Tooth geometries obtained by special grinding with cutting edge hardness up to 1600-3800 HV make the Wikus carbide saw range suitable for the most demanding applications.

These saws are of two types:

With carbide brazed inserts.

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

1 Blades for band saws - types and designs

For modern metalworking, the market offers carbon steel blades, as well as bimetallic blades with a spring base and teeth made of hard alloy or high speed steel. Manifold designs band saws and the use of optimal cutting modes allows to ensure a sufficiently high productivity and significantly reduce the cost of metal processing on band saw equipment compared to other methods of separating cutting of workpieces.

Band saw blades made from quality high carbon tool steel are designed to process a wide range of unalloyed and alloyed alloys. However, in terms of their operational and technical performance, they are significantly inferior to bimetallic band saws, which are more widely used, especially with teeth made of high-speed steel. The basis 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 the M42 high-speed alloy, which is an analogue of 11R2M10K8. This steel, alloyed with cobalt and molybdenum, has high (up to 950 HV) hardness, wear and red resistance. Reliable connection of the base with the cutting teeth is ensured by electron beam welding and allows the use of bimetallic blades in the most difficult production conditions. Saws of a new design, having a combined tooth pitch, are most applicable for cutting products of variable section, profiles, pipes.

The variable pitch can significantly increase the efficiency and stability, reduce the vibration of the cutting process of various workpieces with a variable section.

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

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

The use of these blades can significantly reduce the cost of cutting. Carbide inserts installed in special sockets, the design of which guarantees the reliability of their connection with the saw blade. The set of teeth provides the required clearance during sawing and the necessary removal of chips. These tape blades are used only for processing solid sections 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 workpieces to be cut, it is required to accurately select the technical parameters of the blade: shape, wiring and tooth pitch. Also important are the modes of operation of the band saw itself - the feed and speed of the saw.

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

Wiring - the angle of rotation or inclination of the teeth in relation to the plane of the blade, provides free movement of the edge of the tooth and the band blade. There are the following types of wiring:

• Standard, consisting of a repeating combination of inclination of the teeth - first to the left, then to the right and straight. It is used for all types of steel, especially when cutting soft materials (non-ferrous metals, wood, plastic).
• Variable - a few teeth to the left, a few to the right, a wiper tooth. Reduced noise and vibration are characteristic, it is used for cutting products with a variable section, profiles, pipes, metal packages.
• Wave - for processing thin-walled pipes and profiles, products of small diameter, other thin materials.

Tooth shape:

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

3 The main parameters for the correct operation of the tape web

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

1. workpiece material;
2. which group of alloys and steels the material belongs to;
3. workpiece size.

Based on these data, the tooth pitch is selected. To determine the cutting mode, it is also important which company made the blade for the band saw. Band saw vendors will recommend the best blade speed for a particular type of machine. European-made installations equipped with a stepless speed change variator, which allows you to choose the optimal cutting mode for a particular type of material, have proven themselves well.

In addition, such equipment can be additionally equipped with a built-in blade tension control device (tensometer), which is also important for a significant increase in 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 the chips with the specified design of a certain thickness.

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 are dusty or thin, the feed rate should be increased or the cutting speed reduced. Blue-tinted or thick chips indicate excessive feed or a need to increase cutting speed. Weakly curly - means that the sawing mode is selected correctly.

4 Durability and selection of metal band saws

Saws are characterized by resistance to wear of both the tooth and the blade itself, which experiences alternating cyclic loads that occur during its movement in the tape drive mechanism of the machine. For the products of most manufacturers, the service life of the tape fabric is 140-160 hours of continuous operation of the equipment (subject to all the technological stages of the fabrication process - from its preparation to packaging of the finished one and storage conditions).

Removing the saw during breaks in the operation of the machine provides the so-called relaxation of the blade, which somewhat prolongs its service life. A well-chosen tooth pitch, determined depending on the diameter of the material being processed, has a significant impact on the durability of the tooth. When cutting a package of products for a diameter, the wall thickness is taken as the total thickness of the entire metal that will be sawn. When cutting adjacent pipes, double the wall thickness is used. Below are tables for determining the saw tooth pitch.

For self-selection type of bimetallic tape cloths 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.

Carbide saws of the TCT type are used for cutting difficult-to-machining special alloys, hard materials and materials with a heterogeneous structure.

Saw pitch size for cutting solid steel

Saw Pitch Size for Profile and Pipe Cutting

An indispensable tool in the production of parts of complex shape are band saws. The specifics of the enterprise predetermine the configuration of the equipment, its performance characteristics and the choice of consumables used. The efficiency of work depends on the correct choice of the desired model and the economic feasibility of the application. To do this, you need to know the capabilities of band saw equipment and the principles of working on it. Tape cloths can be made of different varieties 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, construction business. Cutting of plastic and composite materials is carried out. Ferrous and non-ferrous metals are processed. Band saws are versatile. By changing the brand of the blade, its pitch and cutting modes, on the same equipment, it is possible to effectively produce parts from completely various materials. This ensures high accuracy, minimum waste and high speed of operations.

Classification

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

• Saws for wood. Sufficient wear resistance and sharpening quality are important. The part after processing must have a smooth cut with a minimum tolerance for finishing operations. For operations on wood, the canvas is produced in a special version. The tooth pitch, belt width and strength characteristics of steel are calculated. If performance deteriorates, repairs and sharpening are allowed.
• Saws for metal. Depending on the strength of the material being processed, a band saw blade model with the necessary parameters is selected, such as the sufficiency of the strength of the cutting part, the length and pitch of the teeth.
• Universal canvases. They are designed to work with materials of various structure and strength. One saw can work both on metal and on wood. With obvious advantages, there are also significant disadvantages. Such canvases will lose to specialized products of 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 is offset by versatility. There is no need to reconfigure the band saw equipment and change the blade. Several versions are available with various types cutting edge and tooth pitch made of various grades of steel. The width of the canvas is divided into 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 principle of operation. The ability to change the motion vector during the cutting process makes it possible to process curved surfaces with high accuracy. Valuable quality in carpentry, where when working with wood it is often necessary to make parts with complex shapes. Band blades are also effective when cutting profiles and pipes. In terms of popularity, such equipment competes with other devices of this class. Damage can be repaired to restore full performance.

The cutting principle is based on the continuous movement of a steel cutting blade welded into a ring in a special mechanism. This provides a number of operational benefits. The clamping force is directed downwards, and the absence of a reverse motion makes additional fixing of the part optional in some operations. Often, when working on wood, the part is held in the hands, and the cut is carried out according to the marks. The main disadvantage of circular saws, with all their advantages, is the inability to perform a curved cut and the absence of its vertical line. The saw cut always turns out to be radial, repeating the angle and diameter of the disk. The tape is devoid of these shortcomings. The cut 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 the tool is a high-quality joint when forming a loop from a workpiece.

The tape is supplied from the manufacturer in a bay as a whole piece. Then it is cut into pieces and, using a special machine, is welded to the finished product. Ideally, after stripping and grinding the joint, this place should not be noticeable. Production is demanding in all respects. The blade must not lose strength, the roughness of the belt must not exceed the permissible limits, and the shape and pitch of the teeth must be preserved.

The choice of products with different length, thickness, tooth pitch is quite large. The production is trying to offer the maximum choice of canvases for the user with certain geometric and operational characteristics. When purchasing, it is necessary to 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 material feed are basic technical parameters, based on which are determined optimal models saw, tooth pitch and wiring.

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

• Welding. It is used in case of violation of the integrity of the product, loss of part of the teeth or other serious damage. When welding, the steel grade and the joint are taken into account, the requirements for which are the same as in industrial production.
• Cleaning. During operation, sticking of melted particles of the processed material, scale and other foreign substances is possible. This greatly complicates cutting and degrades its quality. The decrease in working qualities does not have the best effect on the main production. After cleaning, the canvas is suitable for installation in band saw. This type of repair is often carried out on site.
• Sharpening. The cutting edge is restored by machining 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.
• Wiring. Required quality for free running of the belt in the material to be processed. Under load during operation, the deviation of the teeth from the blade, set during production, decreases. The saw begins to “bite” or it begins to deviate from the motion vector to the side. Proper wiring will return the necessary performance.

All types of blades can be repaired, both simple models for wood, and bimetal band saws for hard steel grades. Tool recovery improves basic economic indicators making production more cost effective.