Increase the Service Life of Conventional Bandsaw Blades

What is the Bandsaw Blade Break-In Process?

The new bandsaw blade have razor sharp cuting teeth. in order to resist microcracks and cutting pression during sawing processes, it is necessary to break-in the teeth to obtain an extremely small edge radius.

What are the Advantages of the Break-In Process?

To get the best blade life and the highest performance, we recommend that the blade be "broken in".

How to Break-In the Blade ?

1. Determine the proper cutting speed (m/min) and feed (mm/min) based on the material and dimension of the work piece to be cut.

2.It is important to only operate the new saw blade at about 50% of the determined feed during the break-in cuts. This is done to avoid damaging the extremely sharp blade teeth by micro-chipping due to excessive chip thickness. Sometimess new saw blades are prone to vibrations or oscillating noises. If this happens you may reduce the cutting speed. With small work piece dimensions, 300-500 cm² of the work piece cutting material should be cut during break in. When large work piece dimensions are being cut we recommend a break in period of 15 min.

3.After the start-up slowly increase the feed to the previously determined value.

Note: During break-in, slight speed adjustments can be made to minimize vibration and excessive noise. Once the blade has been broken-in, the recommended descent speed should always be used.

In order to get better productivity in your workshops and a longer service life of your band saw blades, it is important to follow certain precautions and to properly maintain the equipment used.

1. Check the coolant level every day. Drain the coolant every 2 months. Clean the tank regularly and especially before adding a new coolant.
2. Lubricate the sawing machine daily.
3. Check daily for leakage from the reduction box. Change the oil on every 10,000 hours of operation or every two years.
4. Before working on the hydraulic pump:
   1. Lower the bow to the lowest position.
   2. Turn the hydraulic pump switch off.
   3. Check the oil level and add if necessary up to the level of the indicator.
   4. Drain annually.
5. Check the hydraulic connections every four weeks for leaks. Tighten the hydraulic and electrical connections.
6. Examine the saw brush every ten hours and adjust if necessary. Make sure the bristles of the brush touch 2/3 of the back of the teeth and make sure of its effectiveness. Do not hesitate to change the brushes.
7. Clean the guides after each saw change. Make sure the guides are not clogged with dirt, especially if you use a spray system (UNIST type).
8. Be sure to clean the flywheel housings every time you change the band.
9. Remove the chips regularly from the machine and thoroughly clean the machine after 100 hours of operation. Do not forget the cutting fluid container.
10. Change the backup battery in your PLC every five years to avoid any loss of data. The switch must be in the on position when changing the battery.
11. Using a quality cutting fluid such as our GLOBE 355, which offers you great protection and control over corrosion and rancidity and helps keep band and work surfaces clean.
12. Note, it is important to dispose of liquids or other waste so as to respect the local rules of the environment.

Every pollution produced by metal working processes and their lubrication is a variable mix of solids and pollutants having different sizes, densities and weights (dusts, aerosols, fumes and odours).

To efficiently make air filtration, means to approach any pollutant using the right media, capable to retain the most dangerous particles. So, to make good filtration, primarily means to catch the pollutants by effective retention, not only through centrifugation or coalescing process.

Big particles can be caught by coalescence or through coarse filtration; therefore the more the particles size is small, the highest must be the efficiency of the filter media, especially because these particles can easily reach sensitive human organs, causing diseases.

That’s why MICRONFILTER takes incredibly care of the filtration media utilized, providing its mist collector ONLY with certified filters. Our mist collectors are allowed to be used even if no final HEPA filters are installed, because our inner cartridges are certified by Independent Institutions (IFA BGIA class “M” certified efficiency 98%). .

MICRONFILTER takes care not only of the air you breath inside working places, but also of the ENVIRONMENT.

Our mist collector units fit a highly engineered, resistant but light fan, capable of providing excellent throughput using much less energy than competitors (averagely 50% less). For any extra kWh used in your factory, half kilogram of CO2 is released in the atmosphere. If just one machine tool, working 3 shafts 7/7 days, was fitted by KUBE unit, instead of some competitor brands, up to 2.000 euro could be saved in money and 1 Ton of CO2 wouldn’t be delivered in the sky.

Exposure to aerosols and mists of neat oils

The analysis of mineral/synthetic oils used for cutting, cooling and lubricating (water chemicals, cutting fluids, neat oils) shows the presence of various additives and preservatives, some of which are classified with the risk rate R40: Possibility of irreversible effects.. Disorders or diseases are related mainly to the following target apparatus: cutaneous, respiratory, hepatic and renal. Regarding exclusively the oils containing PAHs (polycyclic aromatic hydrocarbons), the literature reports the possibility of cancer, with specific reference affection to the skin and respiratory tract. The oils without any PAHs, though much less dangerous, also have the potential to cause diseases including Additionally, the oil mist not removed from the air, due to the gravity, is going to deposit itself on walking surfaces, machine tools, and electronic control devices, creating extremely dangerous conditions for walking and for the use of the tool itself.

Walk in oil polluted areas

The oil mist not removed from the air, due to the gravity, is going to deposit itself on walking surfaces, machine tools, electronic control devices, and any other exposed tool and equipment, creating extremely dangerous conditions for walking and for the use of the tool itself. The adoption of systems of retention at source (mist and dust collectors) prevents this phenomenon, keeping the work premises in optimal conditions and reducing significantly the risks associated with accidents due to slipping, insecure grip objects and similar issues.

About OIL MISTS

Have you ever wondered what is the cost you pay in health and money not taking care of working places pollution? Professional illnesses, accidents at work, low productivity, absences due to disease, are just some of the costs that your Company, yourself and those who works for you, have to endure if you do not face the problem of oil mist pollution in your workplace.The quality of the air you daily breath when at work, is important as you think!

Occupational dermatoses are the second pathology observed in the workplace after hearing loss due to noise and this represents a state of highly disabling disease, the latter being caused by poor air maintenance.

In addition, mineral oils contain potentially carcinogenic substances, which can cause irreversible effects on the respiratory system. For this purpose, excellent air filtration is important to minimize these conditions.

Dont forget COOLANT RECYCLING

The same principles on which we based the project of air filtration units, have inspired our production of coolant filters: take care of the environment, protect workers’ health, reduce pollution and energy waste.

To efficiently use mineral/synthetic oils and their derivates, means primarily TO REDUCE THEIR CONSUMPTION. The better coolants are filtered during the metal working process, the longer will be their life.

Therefore, it is recommended that these substances be filtered directly during metalworking without having to stop production.

Here is an example;

1156 Kg of CO2 are generated for producing 10 Kg of synthetic oil. 1 Kg of synthetic oil released in the ambient can contaminate 1.000.000 liters of pure water.

To filter machine tool coolants and lubricants, regenerating them by proper depuration, is actually the sole way we have for making sustainable their use. ALSO IN THIS CASE YOU WILL SAVE NOT ONLY MONEY.

Never forget their use

The band saw is an essential tool for metallurgical manufacturing. In particular, it allows various forms of cuts to be obtained and guarantees quality cuts with precision. Having this tool, though, is not enough to have good results. In order to obtain quality cuts, the right saw blade must first be chosen, taking into account the use for which it is intended;