Metal band saw. Metal cutting machine

2024 Author: Howard Calhoun | [email protected]. Last modified: 2023-12-17 10:16

Metal band saw is a high-performance equipment responsible for a variety of functions, such as cutting metals and cutting a variety of strong and high-strength materials. This type of equipment is used quite successfully both in the production of metal structures and in the construction industry in order to quickly cut any material. Through the use of a closed thin steel band serving as the cutting element of the band saw, the workpiece is sawn through in a straight line cleanly.

Device Features

If we consider a manual band saw for metal in more detail, then it resembles a jigsaw, since the scheme of their work is similar. There is only one difference - a closed canvas, connected by welding into a ring, does not reciprocate, but along the contour on two pulleys in one direction. This movement pattern allows for a longer saw blade life and also prevents the saw from becoming dull too quickly. This is why band saws become dullnot very soon, that is, they do not need to be replaced too often. The low roughness of the cut plane eliminates the need for surface finishing.

If you use a manual band saw for metal, then cutting rolled products, profiles and pipes will be of the highest quality. Thanks to the special design of the equipment, it is possible to reduce the consumption of electrical energy, as well as to minimize the loss of expensive materials. This is achieved due to the fact that metal cutting in this case is carried out with a minimum kerf width. That is why such machines are increasingly used where work is carried out related to cutting expensive metals and alloys, as well as parts with thin walls.

Efficiency of band saw equipment

If you need a band saw for metal, then you need to know that the market is currently replete with equipment that is controlled in manual, automatic and semi-automatic modes. Manual machines are easy to operate, as reliable as possible, since their design is not burdened with electronic elements that often fail. Their work is carried out with a certain effort and speed, set in advance.

Gravity machines

These devices got their name due to the fact that the cutting of metal blanks is carried out by them due to the pressure of the weight of the console on the material being processed. Hydraulic cylinders and throttle valves are responsible for adjusting the speed of work. Band sawing differencealso lies in the fact that the pitch of the teeth of the blade depends on the profile being cut.

The performance of tape equipment may vary markedly. This criterion allows you to highlight some types of machines.

Cantilever metal cutting machine. In this case, the saw frame (console) moves through the hinge. These models are used for cutting tubes, profiles, sections and solids.

Single-column, double-column and portal. The first type is characterized by a horizontal saw frame that descends along the rack. In two-column, the frame moves along two such columns. They are mainly used for miter sawing and complex processing. Gantry machines are made in the form of a stationary table with a movable portal. This device is used in operations with materials that are difficult to process.

Vertical band saw for metal. With it, you can cut metal along any line, straight or curved. In this case, the workpiece is fed into the working area manually, and the saw frame remains fixed.

Rotary horizontal metal cutting machine. In this case, the frame is rotated around the axis in one or two directions with respect to the right angle of the part axis. This design allows for multi-angle cuts as well as instantaneous adjustment of the cutting angle.

Device Features

The band saw for metal has a whole range of advantages compared to previously releasedbrothers, obsolete morally. The cutting accuracy of such a device is as high as possible, and the resulting surface is of excellent quality. As a result, the manufacturer receives significant material savings, and you can forget about the presence of burrs and nicks at the cutting site. The technique of the described type allows processing blanks in batches. With its help, you can cut both ordinary pipe products and solid billets. The band saw for metal is characterized by a well-thought-out design, due to which the smooth running of the blade and the high speed of the operator are ensured. The mechanism serves for quite a long time due to the presence of a cooling system.

Working principle

In all devices of this category, the same principle of operation is used: the operator manually installs the workpiece on the machine, after which it is fed to the stop, and then the whole cycle occurs in automatic mode, including clamping the material, lifting the saw frame and its feed, squeeze. This equipment is characterized by the highest productivity, as well as the ability to operate in fairly loaded modes in small-scale or single-piece production. As the cutting part of the machines, a steel tape of small thickness is used. On one of its edges there are teeth, and it is called cutting, or front, and the second - back.

Purpose of machines

Machines that work with metal blanks are used quite actively in the field of mechanical engineering. They serve forcutting non-ferrous metals, shaped profiles, pipes to size, as well as solid rolled products. Among their advantages are greater accuracy of work, high productivity, reduced consumption of materials. Band saws for metal, the price of which is quite high and for the smallest models starts from 28 thousand rubles, allow you to get large volumes of products at the output, as well as guarantee the wear resistance of saws if they are correctly selected for the material being processed.

Benefits of using

There are many benefits to working with a band saw:

- high precision cutting;

- quality surface of the resulting cut;

- minimum kerf width, thanks to which the material is consumed very economically;

- cutting blanks in batches.

If an existing production needs an update or improvement, then the right choice would be to choose semi-automatic band saws.

Automatic equipment

This category is characterized by the minimum participation of the operator in the process of work, which greatly facilitates the work. To control the equipment, a CNC system is used, which independently calculates all the necessary actions of the mechanisms. In mass production, the automatic metal band saw performs at its best. The strength and reliability of parts, increased accuracy of work and high quality of cut make it possible to implement the most complextasks.

Semi-automatic two-column machines

This equipment is highly productive, and it is used mainly for working with different steels and alloys. In particular, they are used to cut metal with solid rolled products, as well as elements whose diameter is quite large. They are used for thin-walled materials: profiles, pipes and others.

Features of work

Heavy-duty cast iron castings serve as load-bearing parts for double-column band saws. They are designed to protect the processed materials from the slightest vibrations, as well as from strong shocks and shocks. The movement of the bracket is carried out on four-digit guides. These parts are characterized by increased load capacity, which provides them with the ability to successfully work with forgings, large parts, as well as other elements. The operation of the equipment in a semi-automatic cycle is ensured by a special hydraulic system, characterized by the presence of electric control.

Semi-automatic Double Column Square Cutting Machine

This type of equipment is characterized by the presence of a saw frame placed horizontally. When the task set by the operator is performed, this element moves between a pair of racks located vertically. The saw frame with the bed is connected by a movable connection. Its rigidity, combined with the reliability of the parts used, allows you to create high pressure on the workpiece, which is directedas clearly as possible.

Heavy machines for cutting large workpieces

The extreme rigidity of these machines allows them to be used for cutting large workpieces and materials that are difficult to process. This equipment is used in metallurgical plants. And also in warehouses that are used to store metals. In addition, they can be used in workshops, harvesting areas of various types of high-tech enterprises, where full-fledged work requires the highest productivity per piece of equipment.

Features of work on machines

Working on manual band saws is a rather complicated and time-consuming process, since all operations, in particular, clamping and feeding material into the cutting zone, turning, lowering and raising the saw frame, tensioning the saw, etc., are done by the worker himself. Therefore, they are usually used in small-scale and single-piece production, which are characterized by a small volume of products. Saws for band machines in this case are also used original.

Working on a semi-automatic machine is much easier, since you only need to manually set the workpiece in motion. This equipment is appropriate to use even in medium-scale production. If we talk about automatic machines, then it is important to note their independence in terms of performing all the work. That is why they are actively used in mass and large-scale production. These machines may require band saw welding, but this requiresspecial equipment is used.

Belt cutting technique for metals

To achieve your goals, you need to choose a band with the right tooth pitch. This takes into account a number of factors, among which the most significant is the profile of the sawn workpiece. Moreover, the sharpening of band saws should be of the highest quality. In practice, special tables are used to select the canvas with the desired pitch. When calculating the pitch of the blade, it is necessary to remember that at the moment of cutting, 3-4 teeth are in contact with the workpieces. And here it is not so important what kind of band saw is used (its price is 10 or 250 thousand rubles), it is necessary to select the sizes correctly.