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time2021/06/28
In the field of metal sawing and
processing, when users face the choice of sawing and processing methods, they
often ask a question: "Which processing method is best for my situation?
Choose a band saw or a circular saw?" The business development or cost
control may be affected in the long term.
Band sawing has always been regarded as the
main processing method of metal sawing. Over the years, many subdivisions of
this sawing technology have made great progress, such as:
✦Bundle sawing technology, feed control
technology using servo drive
✦Adopt gear motor to realize low speed and
high torque sawing main drive technology
✦CNC technology for repetitive work
✦High-precision high-speed hard alloy band
saw blade manufacturing technology
✦High-precision sawing processing
technology for difficult-to-cut materials
The above items only represent some of the
functions and advantages of today's band saw technology development.
If the circular sawing machine is used with
a good quality cold saw blade, it has the characteristics of high sawing
precision and high sawing efficiency.
The most basic manual circular sawing
machine can be used for simple and small batch sawing of a variety of
materials, while the automatic closed circular sawing machine is very suitable
for large-scale production, and the material specifications and processing
types are relatively single application scenarios.
A few years ago, it was easier to choose
the answer between a circular saw and a band saw. High-volume, high-volume
applications may require the use of circular sawing machines, and if workpiece
accuracy is not critical, then a cheap band sawing machine may be sufficient.
But today, due to the development of band saw technology, the answer is not so
clear.
What is certain is that in some application
scenarios, the circular sawing method is more economical and effective,
especially where high processing accuracy and high efficiency are required.
Although this equipment is expensive, circular sawing with cold saw blades with
carbide tips can significantly improve sawing efficiency.
However, from the current development
trend, the application fields between these two sawing technologies have begun
to cross each other. Disc heft can still provide high-speed and high-precision
sawing; in the long run, the initial investment of band saws is less, and it
has greater flexibility in sawing capacity, multi-layer sawing and bunch sawing
methods, and currently A high-quality carbide band saw blade coupled with a
good-performance band saw machine may also meet or exceed the workpiece
accuracy and production efficiency indicators that only circular saws could
achieve in the past. For example, in the application of sawing and processing
of aluminum ingots, the current trend is to gradually replace sawing by
circular saws with high-speed band sawing.
1
Influence of material type and material specifications on two sawing
methods
Ask yourself the
following questions first:
What is the diameter of
the sawing material?
Types and grades of
materials to be cut?
Which material is most
commonly sawed?
Saw solid heartwood or
pipe or both?
Will future projects
change demand?
Are you planning to provide other material
models and specifications for the new market?
Generally speaking, the maximum diameter of
circular sawing machine is between 100 and 150mm. If the diameter exceeds
150mm, whether it is measured from the perspective of function or cost, the
band sawing machine should be selected for processing.
Workpieces with a diameter between 25 and
100 mm can be processed using either a band saw or a circular saw. The method
chosen depends on various influencing factors. In the cold cutting process, if
the workpiece needs to be fast-in and fast-out, some common steel types such as
medium and low carbon steel, low alloy steel, tool steel, easy-cut stainless
steel, and aluminum are more suitable for processing by circular sawing
machine, because these materials It is cut quickly by the circular saw, and it
will not affect the machining quality due to excessive heat and friction
leading to premature wear of the cutting edge. However, for difficult-to-cut
materials such as nickel-based alloys and titanium alloys with low cutting
efficiency, more heat and friction will be generated during cutting. When using
a band saw with a much larger number of tooth tips (a
conventional type of belt) The saw has 300 ~ 400 teeth, and a circular saw only
has dozens of teeth to hundreds of teeth). Because each tooth tip has a longer
"rest" time during operation, this processing method is more
conducive to control The temperature of the tool, so this
difficult-to-process material is more suitable for cutting with a band saw.
2
Production demand analysis in history, present and future
You need to know the following information
in this regard:
Hourly, daily, weekly or
monthly?
Are these long-term,
production-oriented, short-term or accidental cutting? Will production demand
shift to mass production in the future?
In any case, what is the
size, grade and quantity of material to be cut?
At present, the band sawing technology has
developed advanced multi-layer sawing and bundle sawing functions, which can
realize high-efficiency and high-precision sawing of small-sized workpieces. If
multi-layer sawing technology is used, then the band saw can be comparable to
the production efficiency of circular saws. On a standard circular sawing
machine, it takes only 10 seconds to cut each piece of Q235 round steel with a
diameter of 50mm, but if five 50mm Q235 round steels are placed on a band
sawing machine, the band sawing machine can also process within 70 seconds
After completion, this cutting efficiency is almost the same as the efficiency
of the circular sawing machine, and may also meet the production needs. If a
high-quality band saw blade is used to set the band saw tension higher on a
double-column band sawing machine with good rigidity and stability, and a
constant control technology for the cutting load per tooth is used for sawing,
the workpiece tolerance and consistency can also be It has been greatly
improved.
Through multi-layer or bundle sawing, the
feeding time can also be greatly reduced. If you are using bundle sawing,
please carefully consider the fixture design. In fact, by using special jigs,
circular saws can be bundled and cut, but only for sawing small diameter
workpieces. As for sawing larger diameter workpieces in a bundle, band saws are
still the only option. Saw cutting of bundles of square or rectangular tubes
may only require horizontal clamping, while sawing of round bar stock will
require clamping in both vertical and horizontal directions, which in some
cases will reduce the sawing capacity because The fixture will occupy part of
the space in the work area, while leaving less space for the material itself.
Nevertheless, the best clamping method is to use both horizontal and vertical
fixtures to reduce vibration during sawing, because excessive vibration will
greatly shorten the life of the tool.
3
Analysis of the accuracy requirements of the processed workpiece
What are the tolerances
for the length, flatness and consistency of the final product?
Is secondary processing
required?
What are the quality
specifications of the finished product?
If the accuracy is improved, can secondary
processing be cancelled, thereby saving processing costs?
If a circular sawing machine uses a cold
saw blade of good quality, the surface of the workpiece cut by the saw is very
smooth, and the burrs on the edge of the workpiece will not exist. But compared
to the current band saw technology, this may not have any obvious advantages.
Now, some high-end band sawing machines use servo-driven ball screw feeding
instead of traditional hydraulic feeding, and are also very precise in length
tolerance and repeatability control. These ball screws on high-end band sawing
machines enhance the precise positioning of materials by improving the
machining accuracy during sawing and eliminating backlash after sawing.
4
Cutting type analysis
Does the material need to be corner cut or
bevel cut? If so, how much angle do you need to reach? What percentage of the
workpiece to be angle cut and bevel cut? Do you need to control these processes
automatically?
If a large number of corner cuts are
required, multi-layer sawing or beam sawing is not feasible in conventional
horizontal band sawing machines. At this time, the cutting efficiency of the
circular saw and the band saw can be compared piece by piece. If the number of
corner cut workpieces is limited, you can choose a horizontal angle miter band
sawing machine suitable for small-sized workpieces.
5
Long-term solution
Try to review the current and future sawing
needs. Management and procurement personnel may consider current expenses,
while manufacturing and operations personnel may consider the long-term
productivity of the machine, both of which are important. Based on the
company's current financial situation, it is important to consider whether it
is important to control the initial purchase cost or whether the machine's
long-term financial investment returns.
If the input and output of a fully
automatic band sawing machine is compared with a fully automatic circular
sawing machine, the cost of the former is significantly lower than the latter.
The most scientific cost evaluation method is to use a cost calculation formula
instead of simply comparing equipment prices. When calculating the cost, it is
necessary to consider whether it is a single piece of sawing or a bunch of
sawing? How many classes do you have every day? What is the daily output? Is
the circular saw blade reground? A large amount of empirical data shows that
the cost per square meter of material cut by a band saw is relatively low.
Taking Q235 material 50mm bar sawing as an example, the cost of band sawing is
about 492 yuan per square meter, while the cost of circular sawing is about 793
yuan per square meter. However, if the circular saw blade regrind is
considered, the unit cost of circular sawing will gradually decrease with the
number of regrinds.
The cost calculation must consider the
operating cost (including power consumption) and the cost of single sawing
(labor and consumables), as well as the preparation time. Based on the number
of processes and other factors mentioned above, it is possible to calculate how
long it will take to compensate for the initial investment of the equipment by
improving production efficiency and the cost savings per saw
In the calculation, it is necessary to
understand the production demand trend, so that the calculation result will be
a good help in measuring what kind of sawing processing method is used to
process the product.
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