FAQS

Technical FAQs & support

We have listed the most frequently asked questions about our WIKUS products. Please feel free to contact our customer service if your have any further questions. 

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Construction of a band saw blade

The abbreviation ‘ZpZ’ stands for teeth per inch (Zähne pro Zoll ) and the number of teeth on a length of 25.4mm. 


When the tooth pitch is constant, the distance between the teeth is uniform; when the tooth pitch is variable, the distance between the teeth differs within a tooth interval.


The benefit of a variable tooth pitch is that it reduces vibration and expands the dimension range that is to be sawn.


The carrier band is made of heat-treated alloy steel. Due to the the way that the band is guided through the machine, the carrier band material must be flexible. The tooth tip area comprises a HSS flat wire that is harder than the carrier band, and must be durable in the machining process, e.g. to prevent broken teeth.

Bimetal Band Saw Blades


A bimetal band saw blade comprises two metals, a hardened high-performance high-speed steel (HSS) tooth tip and a carrier made of heat-treated alloy steel.



Different applications required adapted and specialised tools that differ with respect to the cutting material, tooth geometry and coating.


There are four different band saw blade grades: Tool steel band saw blades, bimetal band saw blades, carbide band saw blades and diamond-studded band saw blades. 
Band selector


Production process of a band saw blade

Setting refers to the angle of the teeth to the body of the band. After setting, individual teeth or groups of teeth protrude left and right across the level of the body of the band. 


The generated cutting channel must be wider than the band thickness to prevent the carrier band from jamming. 


The sanded carbide tooth tips have a greater cutting width than the carrier band, and thereby generate the necessary free cutting. This prevents the band saw blade jamming.


During sand blasting, the tooth base is deburred to avoid rated break points after mechanical processing. To this end, the scale layers are removed after the heat treatment process, and the continuous operation properties are improved by means of surface compaction.


The dimensions of the band saw blade play a decisive role in deciding how the band saw blade should be folded. It is recommended choosing the round folding method for band saw blades (once or three times) for a width/length ratio of up to 41 mm/ 6000 mm. If the band is wider than 41 mm and/or longer than 6000mm, the post horn pretzel form is the most suitable. Depending on the way the bands are shipped or stored, smaller / shorter bands can also be folded in a so-called open pretzel or post horn pretzel form. One exception are the DIAGRIT® bands. These are only folded in a round shape. 


Our product can be kept for an unlimited time if stored properly. 

Information about storage: 
Keep the closed product packaging with the band saw blade in a dry and cool room. Do not expose the band saw blade to moisture (risk of corrosion) and only remove the packaging just before use. Do not stack the bimetal, carbide and diamond-studded band saw blades without tooth protection. 

Terms and conditions


Selection of the correct band saw blade

The tooth pitch is selected based on the maximum contact length of the workpiece/material that is to be cut. The following table provides an overview of the recommended tooth pitch for constant and variable tooth pitches.


The difference lies in the tooth form: VARIO® with a standard tooth "S" = 0° cutting angle and MARATHON® with a hook tooth "K" = 10° cutting angle >> Hyperlink Catalogue page


The following are required to define the properties of a band saw blade precisely: 

  • Band length L in [mm]
  • Band width B in [mm]
  • Band thickness S in [mm]
  • Tooth pitch ZpZ in [inch]
  • Setting and cutting width SW in [mm]

WIKUS provides a decision tool for the selection of the band saw blade that is suitable for your machining task based on the following product classification: 

  • Level 1: Standard band saw blades, universal
  • Level 2: band saw blades with a high performance
  • Level 3: High-tech band saw blades for excellent standards
  • Special: Special products for high-performance sawing technology and very individual applications

Product classification


Compared to bimetal band saw blades, carbide bands achieve a much higher cutting performance including the associated lower cutting times. Also, some materials cannot be machined with bimetal band saw blades due to their alloy components and strengths.


Diamond, as the hardest material, can cut through almost any material. From hard-burnt coal through mineral building materials up to and including silicon.



Thanks to the certification to DIN EN ISO 9001:2015, WIKUS can prove that we look at processes, resources and risks closely, and that we continuously strive to meet customer needs.


We have special band saw blades in our program for this complex application.

ParaMaster® 4.0


We have special band saw blades in our program for this complex application

ParaMaster® 4.0


We have special band saw blades in our program for this complex application

ParaMaster® 4.0


Sawing girders can be complex because the contact lengths differ greatly. We recommend using ParaMaster® 4.0 for this technically complex application and/or contacting our technical support directly.

 


Yes, profiles can be sawn with a band saw. We have special tools for this application in our product program, for instance WIKUS PROFLEX ®  / PROFIDUR®.


In contrast to circular saw technology, it is possible to saw bundles of tubes. We recommend the product PROFLEX ® for this application that is subject to vibration.

 


Our reputed and proven MARATHON® band saw blade is versatile and suitable for a wide range of applications.


Correct breaking-in of band saw blades before they are used for the first time has a major influence on the service life and/or improves the life span of the band saw blade.

Break-in information


The use of diamond-studded band saw blades requires special assistance; we recommend contacting our technical support team. 

Contact technical support


Optimum use of the band saw blades

The band saw blades are coated with a corrosion protection agent which is why the skin protection plan should be observed. If the packaging is damaged, the band saw blade may also be damaged. Damaged band saw blades (in particular with kinks, cracks or broken teeth) may no longer be used.


Caution! band saw blades are under tension. When the attachments are removed, the bands may spring open and pose a risk of injury. To open the bands, place them on the floor and hold tight to prevent the attachments from springing open abruptly.

Video Tech Tips


In general, the occupational safety specifications of the operating company apply. WIKUS recommends wearing at least a long-arm coat, safety shoes, goggles and cut protection gloves when using a band saw blade. 

Video Tech Tips


The following elements all have an almost equal influence on the service life of a band saw blade:  

  • Material form and substances
  • Tool
  • Underlying conditions and cutting parameters
  • Machine tool
  • Cutting data

Service life influences and link to the chart text


During cutting, the blades of the tool move relatively to the workpiece. Even small changes to the blade geometry can have a huge impact on the behaviour of the machining process. Cutting speed (m/min.), the feed movement (mm/min.) and the resulting effective movement directly impact on the formation of chips.


Loads are exerted on the band saw blade both on the tips of the teeth (thermal, impact, abrasive wear), and also on the carrier band (band tension, bending torsion, friction). 


Only use the band saw blade for the specifically defined products (e.g. material groups and other specifications). 
Heat build-up and also flying chips and sparks are possible during use, therefore please always wear protective equipment!
The operating and usage instructions of the machine manufacturer must always be observed.


WIKUS recommends that band saw blades are retracted before being used for the first time! See the details in the individual product descriptions in the catalogue/internet or ask our customer support team.

Retraction information


The right conditions when sawing-in a new band saw blade are decisive for the service life (life span). 
WIKUS recommends:

  • for smaller workpiece dimensions, machine approx. 100-300 cm² of the surface of the cutting material for breaking in
  • if the workpiece dimensions are larger, a time of approx, 15 min is recommended for the break-in
  • after breaking-in, increase the cutting speed (m/min) slowly to the determined value and then gradually increase the feed speed (mm/min) to the previously determined value

Breaking-in


You require the following to determine the optimum machine setting:

  • Material no. (DIN-des.)
  • Material strength
  • Dimensions of the workpiece
  • Dimension
  • Machine type
  • Requirements

Cutting data program ParaMaster®


Based on the following information, WIKUS makes recommendations about the following points: 

  • Quality
  • Tooth pitch
  • Cutting speed
  • Cutting output
  • Feed speed
  • Cooling

Cutting data program ParaMaster®


In machining processes at high speed where heat is generated, it may be necessary to cool the system e.g. with water. In the case of a high cutting load due to a low cutting speed, good lubrication is necessary e.g. oil.


Coolants impact on the service life. The right supply, a suitable medium and the use of a compressed air spray system is important for operation. If possible, the coolant should be applied into the base of the tooth from the front. 

 


Coolants impact on the service life. The right supply, a suitable medium and the use of a compressed air spray system is important for operations. If possible, the coolant should be applied into the base of the tooth from the front.

 


The machine condition, stability and the connected band stability impact on the service life. This is why regular cleaning and checking the condition of the saw machine play an important role. 

Influence the blade-life


Heavy wear, broken teeth, broken welds or a broken band and the slanted/wavy cut could be the causes for a band failure.

 


The band saw blade course must be set correctly; a band tension measuring device can be used for the measurement. Its backing should be attached as closely as possible to the base of the tooth. The measurement should be carried out first on a loose, relaxed band saw blade and then on a taut band saw blade. If the indicator does not point to the upper area of the green marking, the hydraulic band tension should be adjusted according to the operating instructions.


The required oil content of the emulsion depends on the material that needs to be sawn. The emulsion prevents wear, and serves cooling, cleaning and lubricating.


WIKUS usually recommends a band tension of 250-300N/mm².


WIKUS supplies a band tension measuring device for checking the band tension. We will be happy to give you a quote for this device.

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In general, each machine manufacturer specifies the band length for the individual models. This is stated in the operating instructions. If these are no longer available, they can be determined by means of a ParaMaster® query in our online data cutting program

Band Selection


The cutting parameters depend on the contact length, the material and the tempering condition. The WIKUS online cutting data program ParaMaster® 4.0 helps you select the right band for your application, saves on costs and optimises your sawing processes efficiently.


Usually, a band saw blade is replaced if the created surface no longer corresponds to the requirements and/or the cutting process has caused dimensional differences. The standing surface is primarily affected by: Material, strength, cutting performance, and also other underlying conditions such as the condition of the machine, cooling, etc.


Each tooth pitch has its optimum application range. The matching tooth pitch for you is stated in the following table

 


Any more questions?

Our experts in the WIKUS application engineering division will be happy to help you answer further technical questions connected to band selection and use.

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