Bandsaw machine for metal is a high-performance equipment responsible for a number of functions, in particular cutting metals and cutting a variety of durable and high-strength materials. This type of equipment is used quite successfully in the manufacture of metal structures, and in the construction industry to make a quick cut of any material. Thanks to the use of a closed thin steel strip serving as a cutting element of a band saw, the workpiece is sawn clean with a straight line.
Device features
If we consider a manual band saw for metal in more detail, then it bears a resemblance to a jigsaw, since the scheme of their work is similar. There is only one difference - the closed web, connected by welding into a ring, does not reciprocate, but along the contour on two pulleys in one direction. This motion scheme allows for a longer life of the tape web, and also does not allow the saw to become dull too quickly. That is why the saws for tape machines do not dull very soon, that is, they do not need to be replaced too often. The small roughness of the cutting plane eliminates the need for surface finishing.
If a manual band saw for metal is used, then the cutting of 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 electric energy, as well as minimize the loss of expensive materials. This is achieved due to the fact that metal cutting in this case is performed with a minimum cut width. That is why such machines are increasingly used where work related to the cutting of expensive metals and alloys, as well as parts with thin walls, is carried out.
Band saw equipment efficiency
If you need a band saw for metal, then you need to know that the market currently abounds with equipment that is controlled in manual, automatic and semi-automatic mode. Manual machines are easy to operate, as reliable as possible, since their design is not burdened with electronic elements that quite 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 billets is carried out by them due to the pressure of the weight of the console on the processed material. Hydraulic cylinders and throttle valves are responsible for adjusting the speed of work. The difference between tape sawing is that the pitch of the teeth of the blade depends on the profile being cut.
The performance of tape equipment can vary significantly. This criterion allows you to highlight some types of machines.
Cantilever machine for cutting metal . In this case, the saw frame (console) moves through the hinge. These models are used for pipe cutting, shaped profile, long and continuous rolling.
One-rack, two-rack and portal . The first type is characterized by a horizontal saw frame that lowers along the rack. The two-post frame moves along two such columns. They are used mainly for angle 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 in any line, straight or curve. 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 rotation of the frame is carried out around the axis in one or two directions with respect to the right angle of the axis of the part. This design provides opportunities for cutting at different angles, as well as instant reconfiguration of the cutting angle.
Device advantages
Bandsaw machine for metal has a whole range of advantages in comparison with previously released brothers, outdated. 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 place of cutting. The technique of the described type allows the processing of blanks in batches. With its help, you can cut both ordinary pipe rolling and solid billets. Bandsaw machine for metal is characterized by reasonable design, due to which the smoothness of the blade and the high speed of the operator. The mechanism serves for quite some time due to the presence of a cooling system.
Principle of operation
All devices of this category use the same principle of operation: the operator manually sets the workpiece to the machine, after which it is fed all the way, and then in the automatic mode the whole cycle takes place, including clamping the material, raising the saw frame and feeding it, expanding it. This equipment is characterized by the highest performance, as well as the ability to function in fairly busy conditions in small batch or single production. As the cutting part of the machines used steel tape of small thickness. 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 workpieces are used quite actively in the field of engineering. They serve for cutting non-ferrous metals, shaped sections, pipes in size, as well as solid rolled products. Among their advantages can be called greater accuracy, high productivity, reduced material consumption. Band saws for metal, the price of which is quite high and for the smallest models starts from 28 thousand rubles, allows you to get large volumes of output and guarantee the durability of the saws if they are correctly selected for the material being processed.
Benefits of using
There are a number of advantages to processing workpieces on a band saw machine:
- high precision cutting;
- high-quality surface of the resulting cut;
- minimum cut width, due to which the material is consumed very economically;
- cutting blanks in batches.
If an existing production requires updating or improvement, the most appropriate choice will be semi-automatic band saws.
Automatic equipment
This category is characterized by minimal operator involvement in the work process, which greatly facilitates the activity. To control the equipment, an CNC system is used, independently calculating all the necessary actions of the mechanisms. In mass production, an automatic band saw for metal works best. The strength and reliability of the parts, the increased accuracy of work and the high quality of the cut allow us to realize the most complex tasks with it.
Semi-automatic two-column machines
This equipment is high-performance, and it is used mainly for working with different steels and alloys. In particular, they are used to cut metal by continuous rolling, as well as elements in which the diameter is quite large. They are used for thin-walled materials: profiles, pipes and others.
Features of work
Heavy-duty castings of cast iron are used as supporting parts for two-rack-mount 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-bit guides. These parts are characterized by increased carrying capacity, which provides them with the opportunity 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 electrical control.
Semi-Automatic Double Column Cutting Machine Perpendicular
This type of equipment is characterized by the presence of a saw frame placed horizontally. When the task set by the operator is completed, this element makes a movement between a pair of racks located vertically. The saw frame with the bed is connected by a movable joint. Its rigidity, combined with the reliability of the parts used, allows you to create high pressure on the workpiece, which is directed as clearly as possible.
Heavy Duty Cutting Machines
The extreme rigidity of these machines allows you to use them 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, in procurement areas of various types of high-tech enterprises, where full-scale operation requires the highest productivity for each piece of equipment.
Features of work on machines
Work on manual band saws is a rather complicated and time-consuming process, since the worker himself does all the operations, in particular clamping and feeding material into the cutting zone, turning, lowering and raising the saw frame, tensioning the saw, etc. Therefore, they are usually used in small-scale and single-unit production, which are characterized by a small volume of output. Saws for tape machines in this case are also used peculiar.
Work on a semi-automatic machine is much easier, since manually you only need to set the workpiece in motion. This equipment is appropriate to use even in medium series production. If we talk about automatic machines, then it is important to note their independence in terms of all work. That is why they are actively used in mass and large-scale production. For such machines, welding of band saws may be required, but special equipment is used for this.
Metal Band Cutting Technique
To achieve your goals, you need to choose a tape blade having the desired tooth pitch. At the same time, a number of factors are taken into account, among which the profile of the sawed workpiece is the most significant. 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 step. When calculating the blade pitch, it is necessary to remember that at the time 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 choose the sizes correctly.