Cause of Failures

Cause of Failures

The operators, the machine, the material and the band saw blade must form a harmonised system. Here, the operator controls the machine and can impact significantly on the performance and sawing result. In this connection, it is important to know possible failure reasons and their causes to come up with effective countermeasures to remedy these. Wear, broken teeth, broken welds and bands.

Possible failure reasons

  • Heavy Wear
  • Cutting sequence
  • Cracked Weld
  • Bandbreakage
  • Chipping of Tooth


Heavy Wear



Excessive cutting speed

Reduce the band speed, adjust the parameters -> ParaMaster®

Insufficient cooling

Cooling positioned correctly, insufficient quantity

Sand-coated, scale-coated or extremely hard material surfaces and/or hard inclusion in the cutting material.

Adjust the parameters / band type -> ParaMaster®, Clean and/or sand down the material surface in the cutting area if necessary

Wrong initial use.

Observe the break-in regulations -> Break-in

Cutting sequence



Dulling of the band

Change the band

Band guides do not stop the band precisely in the cutting direction, the guide is slanted

Check the guide

The side guides are too loose

Set the mechanical band guides to a gap of 0.02-0.05mm. 

Hydraulic band guides: Check the clamping pressure.

The band guides are too far apart

Position the band guides as close as possible to the cutting material

Feed is too high

Adjustment of the feed -> ParaMaster®

Band tension is too low

Check with the WIKUS band tension measuring device. If necessary, increase the band tension.

Chip brushes damage the tooth blades on one side

Punctual renewal and correct setting of the brushes. 

Cracked Weld



Incorrect production of the welding point

Weld the broken band again, do not dispose of!

Potentially a hidden machine errorChecking the guide elements and traversing wheels of the machine




Guide rollers stand too closely and roll the band

Check the play of the guide rollers and correct, if necessary.

Guide elements are in the wrong position and are not aligned with the two machine impellers

Check and correct, if necessary

Guide elements (band edge/band backing) are worn

Check and replace, if necessary

Band saw blade runs too deeply within the guides

Steps must be taken to guarantee that all the teeth and 1-2 mm of the gullet protrude from the band guides.

Band tension is too high

Check with the WIKUS band tension measuring device. Reduce the band tension, if necessary. Recommended: 250 - 300 N/mm²

Impellers have surface errors

Repair or replace impellers

Conicity of the impellers exert uneven loads on the band saw blade

Repair or replace impellers

Impellers have poor bearings

Set the play of the impeller bearings or replace

The band saw blade backing starts at the collar of the impellers

Adjust the course of the band saw blade (impellers and band guides)

The impellers do not run truly

Repair or replace impellers

Chipping of Tooth



Insufficient band speed

Adjustment of the cutting speed - ParaMaster®

Excessive band feed

Adjustment of the feed - ParaMaster®

Tooth pitch and material cross-section not harmonised

Check tooth pitch and use a band with suitable tooth - Band selector / ParaMaster®

Cutting material is insufficiently clamped / affixed

Better fixation of the workpiece that is to be sawn, especially for layer or bundle cutting

Formation of built-up edges

Checking the cooling and the chip space brush

Hard inclusions in the cutting materialArrange a metallographically investigation of the cutting material, if necessary. Adapt parameter

Any more questions?

WIKUS offers competent technical support to ensure that your machine pool operates as efficiently and effectively as possible. 

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