Application conditions

Application conditions: Factors that influence the blade-life of a band saw blade

Correct breaking-in of saw bands before first-time use has a significant impact on the blade-life! Determine the correct cutting and feed speed for the cutting material based on the material, dimensions and available band saw blade.

First-time use: Break-in guidelines

The right conditions when sawing-in a new band saw blade are decisive for the blade-life (life span). For smaller workpiece dimensions, machine approx.300cm² of the surface of the cutting material for the break-in.  If the workpiece dimensions are larger, a time of approx, 15 min is recommended for the break-in.

After running in, the cutting speed (m/min.) is slowly increased to the determined value and then the feed speed (mm/min.) is gradually increased to the previously deter-mined value. Excessive load due to incorrect break-in leads to micro breaks on the blade edge

Break-in parameters

Bimetal Band Saw blades

approx. 75% of the cutting speed (m/min.) that is suitable for the material and approx. 50% of the feed speed (mm/min.) 

Carbide Band Saw Blades

approx. 75% of the cutting speed (m/min.) that is suitable for the material and approx. 50% of the feed speed (mm/min.)

Identification of the optimum cutting parameters

  • Material no., DIN-des.
  • Material strength
  • Dimensions of the workpiece
  • Dimension
  • Machine type
  • Customer requirements

This results in parameters for the following factors:

  • Tooth pitch
  • Cutting speed
  • Cutting performance
  • Feed speed
  • Cooling

WIKUS recommends using ParaMaster® 4.0 to determine the optimum cutting parameters.


Use of cooling lubricant

Main tasks

Additional tasks

Reduction of friction

Chip discharge

Limitation of the tool wear

Rinsing effect

Reduction of the chipping and reshaping energy

Corrosion protection

Discharge of the friction warmth

 
Guaranteeing a certain surface quality 

Micro-dosing system

  • Spray lubricant onto the teeth of the band saw blade before it enters the workpiece.
  • Only use for short contact lengths.
  • No cooling effect, no rinsing effect.
  • Beneficial when shortening tubes and profiles.
  • Simple retrofitting for vertical bad saws.

Application field:

  • Tubes
  • Profiles
  • Smaller dimensions in the collar
  • Solid material up to Ø 250 mm (construction steel)
  • Solid material up to Ø 100 mm (stainless steel)
  • Aluminium machining

Check the oil content with a hand refractometer and adjust if necessary

The oil content of the emulsion should be adapted to the materials being cut. For more information, please see the cutting data slide(s) or ParaMaster® 4.0, the online cutting data program by WIKUS

Possible consequences of missing cooling

  • Subsequent damage may occur is the cooling system fails
  • Faster wear of teeth (higher temperature)
  • Built-up blade following by broken teeth

 


Use of chip brushes

The correct setting of the chip brush ensures that the chip space is cleaned.
  • Should be driven if possible
  • Cleans the chip space and prevents clogging
  • When using a variable tooth pitch set the tips of the brushes so that they almost touch the shortest tooth base
  • Never use plastic polishing brushes, or only those without abrasive elements
  • Set the brush so that the tip of the brush almost touches the tooth base

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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