The implementation of new developments and the pace of development of science and technology require the use of high-tech equipment in the production. band saw machine for metal fully meets the requirements of the time.
1 Band saw for metal - what is it?
This is a powerful equipment for both straight and figured cutting not only of metal, but also of wood, plastic, and other materials. The working body of the machine is a band saw - a closed (endless) metal strip with teeth. It moves continuously in the same direction closed circuit on 2 or 3 pulleys. The peculiarity of the design and movement of the saw blade provide a long working life of the long cutting surface of the tape. Therefore, the saw slowly dulls and does not need to be replaced frequently.
The power of the electric motor that drives the pulleys determines the productivity and efficiency of the machine, and is the main criterion when selecting a bandsaw blade. Since the forward movement, and therefore the pressure of the saw, is always directed towards the material being processed (toward the working table), there is no danger of the workpiece being thrown into the operator.
The band saw machine for metal is compact and occupies a small area. Series for home workshops, small scale production are light enough and do not require lifting equipment for installation. A high-quality tape blade makes little noise during operation. There are a lot of types and modifications of machines with a band saw, but they all consist of the main structural units:
- frame;
- drive mechanisms;
- saw knot;
- systems for loading and supplying workpieces;
- electromechanical and hydraulic control devices for equipment mechanisms.
2 The principle of operation of the tape machine and its capabilities
As a rule, a belt stretched over 2 flywheels is used in the drive mechanism of the machine. When the equipment is turned on, the belt is set in motion, and the master can load the workpiece for cutting. The cuts made by the machine are very accurate, which is achieved due to the uniform distribution of pressure during metal processing. Cutting on a machine with a band saw is standard (perpendicular to the axis of the equipment) or at an angle (any, not exceeding 60 °).
The second mode is carried out by changing the location of the working body (sawing blade) or by tilting the rotary frame. Cutting at an angle greatly simplifies the processing of workpieces. Coolant (cooling fluid) is used to protect the saws from overheating during operation. It can be water or a liquid viscous composition, continuously supplied to the blade of the blade and washing it. The coolant not only protects the saw from destruction and rapid wear, but also helps to reduce dust from metal particles.
Another one important function- the possibility of equipping the machine with special brushes that continuously clean chips and dust from the blade of the blade. This allows you to get a better and even cut. In addition, the use of brushes also increases the life of the saw and protects the operator from cutting debris.
Used band saws for metal are divided into:
- carbon - for cutting non-alloyed and alloyed steels;
- bimetallic - for heavy cutting conditions;
- carbide - for cutting hard-to-cut metals (alloys with a high content of titanium and nickel, cast iron);
- diamond - for cutting abrasive materials.
3 Classification of tape machines by design
By design, they are divided into groups:
4 Classification of tape machines by degree of automation
According to the degree of automation, machines are divided into:
- manual (gravity);
- semi-automatic;
- automatic.
Usually manual machines are structurally performed as console ones. In them, the saw frame is lowered by the efforts of the worker, overcoming the opposition of the spring. In manual gravity - due to the own weight of the frame. In this case, the feed rate of the frame is regulated by a hydraulic cylinder with a bypass valve. Such a system is called hydraulic unloading, it also serves to lift and fix the frame at the original top point.
The operator of the equipment sets, measures and secures the workpiece in a vise with a manual clamp. The frame lowers at a speed set manually or from a portable control panel.
Advantages of manual band machines for metal:
- low cost, inexpensive operation and maintenance;
- most often, cutting at an angle is possible.
Flaws:
- frame lowering methods often cause the saw to vibrate when cutting and contribute to a sharp decrease in blade life;
- frequent lack of visual control of the degree of saw tension and blade cleaning mechanisms;
- mandatory periodic adjustment of the cutting blade drive pulleys;
- lack of adjustment and control of the pressure of the saw on the part (the valve on the cylinder regulates only the feed rate in a narrow range).
Manual machines are used for small industries for cutting stainless and tool steels, light and non-ferrous metals, both solid blanks and profiles. In semi-automatic band machines, the saw frame is lowered and raised, the vise is clamped and opened automatically by a hydraulic drive. Only the supply of blanks is done manually by the operator.
After starting, the machine fixes the workpiece in a vice, cuts at a given speed. The pressure on the part is carried out not only by the weight of the frame, but also by the force that the hydraulic cylinder creates. This allows you to cut more complex materials (for example, solid stainless steel workpieces). When the saw frame reaches the lower position, the microsensor is activated. After that, the frame is raised to the upper position and the vice is released.
Semi-automatic machines are suitable for small batch production and are the most popular model group. They cut at various angles from -60° to +60°. Design - single-column, two-column, cantilever.
Automatic machines are used in large-scale production for cutting a huge number of serial blanks. The main advantage is that the operator only places the workpiece in a vise and sets the required parameters. After launch, all actions are performed automatically. The cutting force is adjustable at each stage. To prevent the saw from breaking, when the pressure on the blade increases, the smooth feed of the frame slows down or stops. There is a manual mode with control of basic operations.
Automatic machines are more productive, more precise and automatically produce complex bevel cuts. They can operate in a three-shift mode and cut long workpieces into specified fragments without an operator. It is possible to cut workpieces of the same or different lengths in 1 cycle. Design - single-column, two-column, cantilever, vertical, portal.
5 Advantages of cutting on a metal band machine
Machining is the main technological method in the manufacture of parts and mechanisms, machines. The main difficulty in cutting is too large allowances that have to be left for subsequent processing. This is a consequence of the insufficiently high accuracy of preparatory operations and complicates and increases the cost of machining processes.
The most well-known metal cutting methods with chip removal:
- cutters (circular saws) on circular saws;
- cutters or cutters on special cutting equipment;
- hacksaw blades on hacksaw mechanical machines;
- band saws on band machines.
The latter method, in comparison with the others, is characterized by the following advantages:
- higher performance;
- high accuracy– 0.1–1.5 mm, maximum vertical deviation 0.05 mm;
- more high quality cut;
- saving metal consumption due to the small width of the cut (up to 1.5 mm);
- possibility of work at an angle up to ±60°;
- provides cutting of all types of blanks - pipes, long products, solid blanks, forgings, castings;
- the ability to process batches of blanks.
Band saws for metal are designed for sawing metal cylindrical and profile blanks used for subsequent tooling. The JET machine park is represented by a variety of models, each of which has its own specifications, functionality and purpose.
The main distinguishing feature of this type of equipment is that it performs the cutting function, equipped with teeth made of carbide materials. The use of machines allows you to optimize the cost of materials, increase the accuracy of the cut and increase the efficiency of the production process.
Equipment Features
The scope is quite wide, the machines are used in large and medium-sized enterprises. Some types of machines are compact in size, ideal for metalworking in the home. Depending on the processing method, there are vertical and horizontal band saws, each of which has its own scope and technical features. For production purposes, use, and. For each product, the following indicators are characteristic:
console feed method;
indicators of the depth and width of the cut;
minimum and maximum parameters of the width of the tape web;
the ability to cut workpieces at an angle;
web speed parameters;
motor power, its functional features.
The latter category is suitable for both straight and curved cutting. Working body - closed welded seam rotating on pulleys in a given direction. The efficiency of a band cutting machine depends on the power and type of engine, the type of machine and the ability to select the correct cutting conditions.
Depending on the metal being processed and the type of work, different types of saws are selected:
- – for work in heavy modes;
- – for cast iron, alloys with nickel, titanium, etc.
Band cutter suppliers offer the following categories:
- Console (pendulum) - with fastening of a saw frame to a bed by means of the hinge.
- Rotary - ideal for cutting at an angle.
- Vertical - with a frame located vertically (in most cases it is used for cutting sheet blanks);
- Column (single-rack) - with a saw frame moved along a vertical rack;
- Two-column - with fastening on 2 racks, as well as the possibility of cutting at an angle;
- Gantry - for processing large workpieces. The portal moves relative to the workpiece, which is fixed on the table of the machine for cutting material.
General advantages for which it is worth buying band saws for metal:
- Good working resource (10-15 years)
- wear resistance
- Straightness of cut
- Small cutting width and saving, due to this, material
The choice of a band-cutting machine in the company JSC "Rosmark-Steel"
Wholesale and retail prices of machine tools primarily depend on their type. Depending on the purpose of use, you can choose cheaper manual machines, semi-automatic and fully automatic machines.
Band-cutting machines from trusted manufacturers, delivery in the Russian Federation, warranty and after-sales service, assistance in setting up - all this is offered to customers by Rosmark-Stal JSC. Extensive experience of cooperation with large enterprises and small business, availability of our own warehouse and remote technical support guarantee the speed of solving any problem during the purchase and further operation of the equipment.
Band saw for metal is designed for continuous cutting of round steel, pipes of various diameters, angles and channels made of non-ferrous and ferrous metals. High efficiency and quality of metalworking is ensured through the use of band blades made of heavy-duty steel and reinforced with cobalt or hard alloy inclusions.
Band saws for metal have a wide range of applications. They are in demand both at industrial enterprises and in small workshops, school workshops, and service stations. Often cutting is done at right angles. Band saws for metal, equipped with a rotary frame, are able to cut workpieces at an angle.
Classification of band saws according to the degree of equipment automation
- manual type machines, in which the lowering of the saw frame is carried out using the operator's muscular strength, and the equipment is returned to its original position by a spring or hydraulic drive. Installation, fixing in the vise of the workpiece is also carried out by the operator of the equipment.
- semi-automatic band saw machines automatic mode the saw band is lowered onto the workpiece, returned back, and fixed in a hydraulic vice. The operator only needs to manually feed the workpieces. The most common type of band saws due to the optimal ratio of price and functionality.
- automatic equipment used for series production cutting blanks according to the program specified by the operator. Mainly used in large industrial plants for continuous cutting of various profiles, pipes.
Main characteristics
Before buying cutting equipment, we recommend evaluating the main parameters of the selected units:
- power;
- maximum allowable dimensions of parts;
- angle of rotation of the working unit;
- saw characteristics;
- cutting and feeding speed of the workpiece;
- cutting width in the transverse direction;
- cut size;
- maximum length of cut blanks;
- weight and size parameters of machine equipment;
- its cost.
In our online store, band saws for metal are available on the most favorable terms in Moscow. Direct cooperation with leading manufacturers of the industry allows us to form an acceptable price, guarantee the original quality and long working life of band saws for metal. We provide a 1 year warranty on all units.
The company "Rustan" is a reliable supplier of machine tools of Russian and foreign production.
In modern world industrial enterprises are increasingly moving to high-tech equipment. This phenomenon is explained by scientific and technological progress and the need to sell the goods that are produced in the process of this progress. The band saw machine for metal is one of the brightest representatives of such equipment.
The device is a high-power unit capable of cutting not only metal blanks, but also wood, plastic, and much more. Band saw cutting of metal makes it possible to cut both straight and curly. The main working element of machines of this type is a closed-type toothed metal strip, which has one direction of movement, performed using two or three pulleys.
The main feature of such a device is the platform of the cutting strip of good length. That is why the toothed saw of this type of machine tool remains sharp for a long time, without requiring replacement many times a year.
The power of the electric motor, which is responsible for the movement of the pulleys, is the very characteristic responsible for the efficiency and productivity of this type of unit, therefore it is one of the main arguments when buying a band saw.
Such a device has a low degree of danger because the cutting blade here is directed to the side of the working surface and the element being processed, so the operator simply cannot get injured due to the ejection of the processed material in his direction.
Manufacturers
The main manufacturers who specialize in the manufacture of machines of this type are world leaders in the field of machine tool building:
- Italy (CARIF).
- Germany (KASTO, BEHRINGER).
- Japan (AMADA, DAITO).
- Korea (DELTA).
- Taiwan (EVERISING).
- Czech Republic (PROMA, BOMAR).
- Switzerland (JET).
- Spain (DAVONA).
- United States (DOALL).
Band saws are very compact and lightweight, which does not interfere with their power and high efficiency. It is quite possible to install them with your own hands, without using lifting equipment. Also, the list of advantages of this device is supplemented by a good level of sound insulation when using a tape strip. good quality.
Design
Each brand of band saw machine, regardless of characteristics, consists of the following structures:
- frame;
- drive mechanisms;
- structural unit responsible for cutting elements;
- a mechanism that loads and feeds parts for processing;
- a system that controls the mechanisms of the device, which includes hydraulic and electromechanical elements.
Groups of band saws by design:
- Portal - the working surface is in a stationary state, and the assembly with the saw frame is movable.
- Vertical manual - a band saw for metal is designed in such a way that the workpiece is not clamped in a vice, but is held and fed by one's own hand.
- Pendulum - when the saw frame moves up and down, while rotating on a hinge. This type of band saw is used for cutting pipes and profiles. They can cut at right or oblique angles. There are automatic, semi-automatic and handheld devices.
- Double-column - the saw frame is in a horizontal position and moves along two racks located vertically on both sides of the working surface.
The principle of operation of the band saw machine and its capabilities
A belt stretched over two flywheels is the main element of the drive mechanism for almost all models of band saws. It begins its movement immediately after the start of the equipment. This means that you can start working only by turning on the machine.
The design of the band saw machine allows you to distribute even pressure on the workpiece, which, in turn, makes it possible to obtain fairly thin cuts. Also, cutting in this device can be performed both perpendicular to the axis of the machine, and at an angle that does not exceed the mark of sixty degrees.
At long work the cutting saw heats up and often fails. To avoid this, use a cutting fluid at the cutting site. This substance protects the work surface from rapid wear and prevents metal dust and sawdust from entering the environment. For this purpose, either plain water or a liquid with a special composition is used, which cools and lubricates the cutting tool.
Some manufacturing companies attach special brushes to the machine mechanism, which are constantly cleaning the working platform from dust and dirt during the processing of the necessary part. Thanks to such a simple device, the evenness and accuracy of the cut is much higher, as well as the safety of the operator while working with this device is increased and the service life of the machine is significantly extended.
Degrees of automation
A manual band saw for metal is similar in design and mechanism of action to a cantilever. In this class of band saws, the saw band moves with the help of the physical efforts of the worker or due to the own weight of the frame itself. Their advantages:
- Rather low cost of both the equipment itself and its maintenance and operation.
- In most cases, cutting can be done at an angle of up to sixty degrees.
Flaws:
- The manual method of lowering the saw frame causes the saw to vibrate during operation, which reduces the life of the machine.
- In most cases, there is no visual control of the degree of tension of the saw itself and the mechanisms responsible for cleaning the working platform.
- During manual operation, it is necessary to periodically adjust the blade drive pulleys.
Most often, such manual devices for cutting metal on a band saw machine are used by small industrial production.
Semi-automatic band saws for metal, in which the mechanisms are driven by a hydraulic drive. From self made the operator can only feed the blanks.
Work with a workpiece in a semi-automatic machine is performed in this way:
- After starting the tape machine, the workpiece is automatically held.
- A special hydraulic cylinder provides a certain cutting speed and pressure.
- The lifting of the saw strip after reaching the bottom point of the cut is done automatically.
Automatic machines are mainly used in large enterprises for cutting a large number of workpieces. The main advantage of this device is that there is no need for the use of physical effort - the worker can only put the part in a vise and set the necessary parameters for processing.
If the need arises, then tape machines of this type are easily transferred to manual control mode.
Video: JET MBS-56CS - metal band saw.
Main benefits of work
Cutting metal with a band saw is one of the main technological methods its processing in the manufacture of the necessary elements. The main difficulty when working with tape machines is the appearance of very large allowances, which operators are forced to leave for the next processing.
The main metal cutting methods that include chip removal are:
- Milling cutters on circular saws.
- Cutters on a cutting unit of a special type.
- Hacksaw strips on a hacksaw mechanical type.
- Abrasive wheels (vulcanite or diamond).
- Band saws.
In the latter case, the following advantages can be distinguished:
- high performance;
- high accuracy and minimum deviation during operation;
- high quality cut of the workpiece;
- economical use of metal;
- cutting workpieces of various types;
- batch processing.
The band saw machine can be used not only for cutting metal, but also for processing elements from various other materials. Such a machine is efficient, compact and easy to use, but at the same time it has high power. In the modern world, there is a huge selection of high-quality machine tools of this type, such as the JET metal band saw.
You can save a lot if you buy a used band saw for metal. This equipment is perfect for both small workshops and for large enterprises involved in the processing of elements from various materials.