Proper usage and maintenance is the only way to ensure that your band saw blade serves you diligently. These precautionary measures are bent on enhancing safety when using the product. Consequently, the enhanced safety will ensure that the blade is effective while in use. There are several factors that can lead to a poor performance by your blade. Some of the factors include band breakage, stripping teeth, premature cutting of teeth, rough cuts and crooked cuts:
- When new, the band saw blades are too sharp. Therefore, all the blades need to be broken in. For the best performance, it is recommended that you engage the appropriate band speed. In addition, you should consider reducing the feed pressure to about half the normal rate. These settings should be applied on the first 50 inches of the material being cut. However, if the material being cut is low or mild carbon steel, the settings should be applied on the first 150 inches of the material.
- Another important aspect to bear in mind is the SFPM for the different speed settings that you are going to apply. This will help you in determining the ideal speed to use on the material you intend to cut. By considering the SFPM, you are assured of a more effective and a longer lasting band saw blade. In order to achieve the desired results, you need to determine the appropriate RPM to use and also measure the diameter of the wheel. There are many ways through which you can determine the RPM. The operator’s manual will act as an important guide in determining the RPM. In addition, you can also calculate the revolutions made by the wheels per minute by using a revolution counter or a tachometer. Thereafter, measure the drive wheel’s diameter in inches and multiply the diameter by 0.262 in order to determine the wheel’s circumference. The result of this multiplication is equal to the speed of the blade. Always bear in mind that premature blade problems are real. Therefore, take preventive measures by regularly checking your blades.
- Stripping teeth is a major problem in most blades. In such an instance, the teeth on the blade shred the material being cut. This problem can mainly be as a result of very many or very few teeth working on the material being worked on. When the parts are not securely held, the feed rate is too high or the speed may be too low. This causes the chip brush not to work since the chips are overloading gullets. This means that the concentration of the coolant is not where it needs to be so as to effectively run the blades.
- Band breakage is another common problem encountered. In most cases, this problem occurs as a result of the blade aging. In addition, overstressing the blade can also cause band breakage. If the other equipment is aging, this might stress the blades. Other factors that can lead to band breakage are: worn out guides, guide arms being set too far apart, wheels having a very small diameter, too much tension on the band and also poor welding on the equipment. In order to reduce band breakage as a result of small diameter on wheels, it is advisable to use thinner bands.
- Crooked cuts are also experienced when using faulty blades. There are various results which can be attributed to the crooked cuts. Some of the factors causing these cuts include: blade being improperly broken in, dull blade, guide arms being too far apart or not properly aligned, damages roller or carbide guides, heavy feed rate, slow speed or vise clamp being out of square.
- Improper maintenance of the blade can lead to premature dulling of the blade’s teeth, thus leading to rough cuts. Dulling of teeth can also be caused by: poor blade break in, coolant concentration and flow being inconsistent, faulty chip brush, improper deed rates and blade speed or improper tooth pitch.
The power to ensure your blade works effectively is in your hands. The only solution is putting into place the proper maintenance practices. Therefore, if you know which signs to look out for in order to enhance proper maintenance, you are assured of a blade that will: serve you for long, work effectively and also enhance a better environment for working.