Band Saw Trouble Shooting

The members of the North American Sawing Association (NASA) recognize that a band saw machine and band saw blade need to be properly matched to achieve peak performance. The majority of band sawing difficulty is caused by misapplication due to incorrect feed, speed, cutting fluid ratio, tooth selection and machine repair. It is important for saw blade users to continually train their operators and seek the latest insawing technical data and utilize preventive maintenance to ensure a cost effective cutting application.

Blade Effect		Probable Cause	Solution
		Incorrect Blade Band tension too high Excessive feed Incorrect cutting fluid Wheel diameter too small for blade width Worn or chipped pressure block Blade rubbing on wheel flange Teeth in contact with work before starting saw Side guides too tight	Check tooth selection Reduce band tension, refer to operators manual Reduce feed pressure Check coolant recommendations Use narrower blade Replace worn pressure blocks Adjust wheel alignment Allow blade clearance above work Refer to operators manual
		Blade on machine backwards Improper blade break-in procedure Hard material or heavy surface scale Material is work hardening Improper cutting fluid or mix ratio Speed or feed too high	Install blade correctly Refer to recommended procedures Check material hardness and surface condition Increase feed pressure Follow coolant mixing procedures Adjust wheel alignment Check cutting recommendations
		Guide arms too far apart Blade worn out Over or under feeding Improper tooth pitch Cutting fluid not applied properly Too many teeth for material cross section Guides worn or loose	Adjust guide arms closer to material Replace blade Check cutting recommendations Use proper tooth selection Adjust coolant nozzles Use proper tooth selection Tighten or replace guides
		Over feeding Low band tension Tooth set damaged Guide arms loose or space too wide	Check cutting recommendations Refer to operators manual Check material hardness Adjust guides and guide arms
		Worn or missing chip brush Improper or lack of cutting fluid Wrong coolant ratio Excessive feed or speed Incorrect blade pitch	Replace or adjust chip brush Check coolant flow and fluid type Check coolant type and ratio Reduce feed or speed Use proper tooth selection
		Saw guides not properly adjusted Incorrect feed or speed Incorrect blade Material moved in vise	Align or adjust saw guides Refer to cutting recommendations Use proper blade type and pitch Inspect and adjust vises
		Indexing while blade in work Blade not high enough before index Saw head drifts into work while neutra	Adjust index sequence Adjust height selector Check hydraulic cylinder
		Improper blade break-in procedure Speed too slow Tooth jammed in cut Poor cutting fluid application or ratio Hard material or heavy scale Wrong blade pitch Work spinning or loose nested bundles Blade on backwards	Follow proper break-in procedure Refer to cutting recommendations Reduce feed pressure Do not enter new blade in that cut Adjust coolant flow and ration Check material or surface hardness Use proper tooth selection Tighten vises or use nesting clamps Install blade correctly
		Excessive back-up guide preload Low blade tension Incorrect blade (carbon steel type) Excessive feed rate or pressure Damaged or worn pressure block Guide arms spaced too far apart Blade rubbing band wheel flanges	Adjust pressure blocks Refer to operators manual Switch to a Bimetal blade Reduce feed rate or pressure Replace pressure block Adjust guide arms closer to work Adjust wheel alignment
		Dull or damaged blade Incorrect feed or speed Blade not supported properly Low blade tension Incorrect tooth pitch Guide arms too far apart	Install new blade Refer to cutting recommendations Adjust or tighten guide arms Refer to operators manual Use proper tooth selection Adjust guide arms closer to material
		Saw side guides too tight Blade riding too high in guide Blade teeth riding on band wheel surface Wrong blade width for machine Chips be carried back into cut Worn or damaged pressure block Insufficient coolant flow	Adjust guides properly Adjust rollers or pressure blocks Adjust tracking or replace wheel Refer to operators manual Replace or adjust chip brush Replace pressure block Adjust coolant flow
		Blade binding in cut Side guides are too tight Work loose in vise Feed to heavy Guide arms too far apart	Adjust feed or use heavy set blades Adjust guides Adjust vises Reduce feed pressure Adjust guide arms closer to material
		Incorrect blade Heavy feed or too fast speed Lack of cutting fluid Blade installed backwards	Use proper tooth selection Refer to cutting recommendations Adjust coolant flow or ratio Install blade correctly
		Material loose in vise Incorrect tooth pitch Feed too fast Speed too fast	Adjust vises Use proper tooth selection Reduce feed rate Refer to cutting recommendations

Guide To Using A Metal Band Saw

Depending on how you will use your metal band saw, you can either cut with a vertical band saw or a horizontal band saw. For cutting straight lines you should problably use the vertical band saw. This is a stand alone saw that is a larger piece of equipment and has four legs typically with rubber feet to keep it from moving while you are cutting material. Do not get your hands close to the blade. Use a long metal device, at least 6 to 12 inches long to help you feed the material through when it gets close to the blade. The material being cut with the saw must be securely fastened to a cutting table so a smooth cut can be achieved. The saw blade is pushed through the metal to make the cut. Most horizontal saws turn off automatically when they finish the cut. They are used for straight cuts, cutting rolls and curves.

The wheels that hold the blade on the saw are the drive wheel, which is attached to the power source and the idler wheel which is loosened or tightened depending on how tight the blade needs to be. The saw can be powered hydraulically or it can be powered with an electric motor. A blade guide is used to keep the blade securely in place and to guard the blade. The wheel sizes can be larger or smaller depending on what is being cut. Always remove the blade from the saw when you have finished cutting. The reason it is important to do this is that there is tension on the blade when it is on the saw. The cutting process will make the blade very hot. The heat has caused it to expand a little bit. The cooling process will cause it to shrink. If there is tension on the blade during cooling, it can crack or even break the blade. Be sure to wear gloves when removing it.

Follow safety precautions anytime you use a metal band saw. You are going to have a large amount of sparks flying during the cutting process. Be sure that you are not cutting near flammable liquids that may explode or near other material that may catch on fire from the sparks. Wear protective eye goggles always. Wear tight fitting clothes that will not get caught in the blade of the saw. Be sure that you have adequate ventilation. Even if it is cold outside, you need to have at least a window open.

If you are the type who wants to impress your friends by using your band saw for strange things like cutting your hair or finger nails be prepared to see a lot of your own blood flowing out of your body. There have been stories of people showing off and causing extreme injury to themselves and others. This saw is not toys so use it correctly.

article by John Humphries

Guide To Cut Metal With A Band Saw

How do I cut metal with a band saw? In this post, we will take a look at what you need to know about different types of metals and how to cut them, the equipment you will need to do it, and the accessories that are required to do it safely.

When most of us think of metal we think of the big steel coils we see on tucks going down the free way or the big beams used to erect a building. I doubt this is the type of steel that you will be cutting. I'm guessing that you will be dealing with tubing, pipe, rounds, squares, angles, channels, flats and maybe even some light beams. These items also come in a wide variety of material types, such as carbon steel, stainless steel, aluminum, bronze, and a whole bunch of alloys and specialty metals too. Knowing the type of metal that you plan to work with will make all the difference in how easy it is to work with and cut on your band saw. For instance, if the blade you are using is supposed to be used for cutting aluminum, do you think it will work well on stainless steel? Not at all! Stainless steel is very hard and requires a special blade to cut it effectively. Using the wrong blade could cost you time and money. Make sure you have the right blade for the right material type your working with. Metal blades generally have smaller teeth and much more of them over the length of the blade. This is so that the blade removes smaller pieces of metal and doesn't bind up while cutting. Wood blades have much bigger teeth that are spread out a little more. Talk to someone who knows blades when you're looking to buy one for your next project. They should also be able to help you with the proper cutting speeds and feed speeds for your saw.

Another consideration is dealing with how the material is cut. Take wood for instance, you can take a piece of wood and run it through a band saw without having to clamp it in a vice. Just set it on the table and push it through, no problem. Try this with a piece of metal and you're sure to be on your way to the emergency room. When cutting metals of any kind, you must use some sort of vice or clamping device to keep the piece from moving on you. Even though the blades are smaller, the teeth will still grab the metal and bind up. In this battle between man and machine, the machine will normally win. Most band saws used for cutting metal are strictly for cutting metal. Whether vertical of horizontal, they will have some sort blade speed control and also have a way to control the feed speed of the blade. This means that the blade travels either up or down on a horizontal saw or back and forth on a vertical saw and travels on it's own. Another device that a metal saw has that a wood saw does not is a way to supply cutting fluid. As you would guess, cutting metal with metal will create a lot of friction. A metal saw will have a way to deliver cooling fluid to your blade where it comes into contact with the metal, thus keeping it cool. Without it, your blade would simply heat up and break.

I do not recommend trying to cut metal on a wood saw that you have converted over to a metal saw by simply applying a metal blade to it unless you have been in the industry for a long time and know what your doing. If you are reading this article, I'm going to say you don't, so don't do it.

Finally, take note of a few safety accessories you will need and make sure you use them. Safety glasses are a must! Metal fragments fly off these saws like crazy, you don't want one going in your eye and it does happen. Use good leather gloves when handling the material, but never have them near the blade while the saw is running. Trust me on this one, I had a friend that learned this the hard way and lost his thumb! Make sure your blade has a guard on any areas of the blade that are not used for cutting. A lot of the older saws weren't required to have guards, so you may have to make them yourself.

If you follow these principles, you will be on your way to cutting metal safely with your band saw. I would also recommend that you take a course on band saw safety from a local distributor of saws or from a local technical school. The limb you save may be your own!

source by www.essortment.com