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Chapter

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Sawing and Cutoff Machines

LEARNING OBJECTIVES
After studying this chapter, you will be able to: H Identify the various types of sawing and cutoff machines. H Select the correct machine for the job to be done. H Mount a blade and prepare the machine for use. H Position the work for the most efficient cutting. H Safely operate sawing and cutoff machines. There are three principal types of metal-cutting saws, Figure 12-2. Reciprocating power saws use a back-and-forth (reciprocating) cutting action. The cutting is done on the backstroke. The blade is similar to that found on a hand hacksaw, only larger and heavier. Band-type power saws have a continuous blade that moves in one direction. Circular-type power saws have a round, flat blade that rotates into the work. A toothed blade, friction blade, or abrasive blade may be used, depending on the material and the operation.

Cuts only on this stroke

Abrasive cutoff wheel, circular toothed blade, or circular no tooth blade (friction cutting)

Reciprocating type power saw Continuous cutting

Circular type saw

IMPORTANT TERMS
all-hard blade cold circular saw dry abrasive cutting flexible-back blades friction saw gravity feed horizontal band saw raker set three-tooth rule wet abrasive cutting

12.2 RECIPROCATING POWER HACKSAW

A reciprocating power hacksaw, Figure 12-3, uses a blade that moves back and forth across the work. The blade cuts on the backstroke. There are several types of feeds available. Positive feed produces an exact depth of cut on each stroke. The pressure on the blade varies with the number of teeth in contact with the work. Definite pressure feed yields a pressure on the blade that is uniform regardless of the number of teeth in contact with the work. The depth of the cut varies with the number of teeth contacting the work. This condition prevails with gravity feed. Feed can be adjusted to meet varying conditions. For best performance, the blade and feed must be selected to permit high-speed cutting and heavy feed pressure with minimum blade bending and breakage. Standard reciprocating metal cutting saws are available in sizes from 6 6 (150 mm 150 mm) to 24 24 (900 mm 900 mm). The saws can be fitted with many accessories, including quick-acting vises, power stock feed, power clamping of work, and automatic cycling of the cutting operation. The latter moves the work out the required distance, clamps it, and makes the cut automatically. The cycle is repeated upon completion of the cut.
191

Band type power saw

Figure 12-2. The three principal types of cutoff saws.

Variable feed setting Feed reverse control

Positive feed setting Feed lever

Four-speed transmission

12.1 METAL-CUTTING SAWS

The first step in most machining jobs is to cut the stock to required length. This can be done using power saws, Figure 12-1.

Start and stop buttons Quick action vise handle

Saw blade

Length gage

Figure 12-1. The first step in most machining jobs is to cut the stock to the desired length. Measure the cutoff length carefully and observe all safety precautions. (DoALL Co.)

Figure 12-3. An industrial reciprocating power hacksaw. (Armstrong-Blum Mfg. Co.)

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Machining Fundamentals Avoid make sure movable jaw of vise fits solidly against work

High-speed cutting requires use of a coolant. Coolant reduces friction, increases blade life, and prevents chip-clogged teeth. Cast iron and some brass alloys, unlike most materials, do not require coolant. A swivel vise permits angular cuts to be made quickly. See Figure 12-4.

Figure 12-4. A swivel vise permits angular cuts.

12.2.1 Selecting a Power Hacksaw Blade

Proper blade selection is important. Use the three-tooth ruleat least three teeth must be in contact with the work. Large sections and soft materials require a coarse-tooth blade. Small or thin work and hard materials require a fine-tooth blade. For best cutting action, apply heavy feed pressure on hard materials and large work. Use light feed pressure on soft materials and work with small cross sections, Figure 12-5.

Blades are made in two principal types: flexibleback and all-hard. The choice depends upon use. Flexible-back blades should be used where safety requirements demand a shatterproof blade. These blades should also be used for cutting oddshaped work if there is a possibility of the work coming loose in the vise. For a majority of cutting jobs, the all-hard blade is best for straight, accurate cutting under a variety of conditions. When starting a cut with an all-hard blade, be sure the blade does not drop on the work when cutting starts. If it falls, the blade could shatter and flying pieces cause injuries. Blades are also made from tungsten and molybdenum steels, and with tungsten carbide teeth on steel alloy backs. The following rule-of-thumb can be followed for selecting the correct blade: Use a 4-tooth blade for cutting large sections or readily machined metals. Use a 6-tooth blade for cutting harder alloys and miscellaneous cutting. Use 10- and 14-tooth blades primarily on light duty machines where work is limited to small sections requiring moderate or light feed pressure.

Many techniques have been developed for properly mounting and tensioning blades. Use a torque wrench and consult the manufacturers literature. If the information (proper torque for a given blade on a given machine) is not available, the following methods can be used: Tighten the blade until a low musical ring is heard when the blade is tapped lightly. A high-pitched tone indicates that the blade is too tight. A dull thud means the blade is too loose. The shape of the blade pin hole can serve as an indicator of whether the blade is tensioned properly. When proper tension is achieved, the pin holes will become slightly elongated, Figure 12-7.

Solid vise jaw

Movable vise jaw

Figure 12-8. If the work is not clamped solidly, it will twist and the blade will bind and be ruined in the first few seconds of use.
Set stop gage high enough to allow cut piece to fall away from blade

Mounting pin Saw frame

12.2.2 Mounting a Power Hacksaw Blade

The blade must be mounted to cut on the power (back) stroke. The blade must also lie perfectly flat against the mounting plates, Figure 12-6. If long life and accurate cuts are to be achieved, the blade must be properly tensioned.
Blade must be Direction seated solidly of cut against mounting plate

Elongated mounting pin hole

Heavy feed pressure

Figure 12-7. Pin holes on a properly tensioned blade will be slightly elongated, rather than round.

Large work or hard metals

The blade will become more firmly seated after the first few cuts and will stretch slightly. The blade will require retensioning (retightening) before further cutting can be done.

Figure 12-9. A stop gage is used when several pieces of the same length must be cut. Set it high to permit the work to fall free when completely cut.

12.3 POWER BAND SAW

The horizontal band saw, Figure 12-10, is frequently referred to as the cutoff machine. It offers three advantages over the reciprocating hacksaw: Greater precisionThe blade on a band saw can be guided more accurately than the blade on the reciprocating power saw. It is common practice to cut directly on the line when band sawing, because finer blades can be used.

12.2.3 Cutting with a Power Hacksaw

Light feed pressure Tap blade lightly and listen to ring

Small work or soft metals

Figure 12-5. Apply heavy feed pressure on hard metals and large work. Use light pressure on soft metals and work with small cross sections.

Figure 12-6. The blade must be adjusted to cut on the back stroke. Make sure it is perfectly flat against the mounting plates before tensioning. Tighten the blade until a low musical ring is heard when the blade is tapped with a small hammer. Since blades have a tendency to stretch slightly after making a few cuts, tension should be checked and, if necessary, adjusted.

Measure off the distance to be cut. Allow ample material for facing if the work order does not specify the length of cut. Mark the stock and mount the work firmly on the machine, Figure 12-8. If several sections are to be cut, use a stop gage, Figure 12-9. Apply an ample supply of coolant if the machine has a built-in coolant system.

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Faster speedThe long, continuous blade moves in only one direction, so cutting is also continuous. The blade can run at much higher speeds because it rapidly dissipates the cutting heat. Less wasteThe small cross section of the band saw blade makes smaller and fewer chips than the thicker reciprocating blade, Figure 12-11.
Kerf made by cutoff wheel By power hacksaw By band saw

Tooth pattern determines the efficiency of a blade in various materials. The standard tooth blade pattern is best suited for cutting most ferrous metals. A skip tooth blade pattern is preferred for cutting aluminum, magnesium, copper, and soft brasses. The hook tooth blade pattern also is recommended for most nonferrous metallic materials. See Figure 12-13. For best results, consult the blade manufacturers chart or manual for the proper blade characteristics (set, pattern, and number of teeth per inch) for the particular material being cut.

Blade guides

A
Figure 12-14. Adjust blade guides to provide adequate blade support; otherwise, blade will not cut true. (W.F. Wells)

Standard tooth

Skip tooth

This typically includes checking wheel alignment, guide alignment, feed pressure, and hydraulic systems.

Figure 12-11. Differences in the amount of metal converted to chips (waste) by each cutoff machine.
Hook tooth

12.4 USING RECIPROCATING AND BAND SAWS

Most sawing problems can be prevented by careful planning and observing a few rules. These apply to both reciprocating and band saws.

12.3.1 Selecting a Band Saw Blade

Band saw blades are made with raker teeth or wavy teeth, Figure 12-12. Most manufacturers also make variations of these sets. The raker set is preferred for general use.

Figure 12-13. Standard tooth blades, with rounded gullets, are usually best for most ferrous metals, hard bronzes, and hard brasses. Skip tooth blades provide for more chip clearance without weakening the blade body. They are recommended for cutting aluminum, magnesium, copper, and soft brasses. Hook tooth blades offer two advantages over skip tooth blades easier feeding and less gumming up.

12.4.1 Blades Breaking

Blades are normally broken when they are dropped on the work. A loose blade or excessive feed can cause the blade to fracture. Loose work can also cause blade damage, as will making a cut on a corner or sharp edge where the three-tooth rule is not observed. Broken blades can normally be avoided with proper machine setup.

12.3.2 Installing a Band Saw Blade

If the saw is to work at top efficiency, the blade must be installed carefully. Wear heavy leather gloves to protect your hands when installing a band saw blade. Blade guides should be adjusted to provide adequate support, Figure 12-14. Proper blade support is required to cut true and square with the holding device. Follow the manufacturers instructions for adjusting blade tension. Improper blade tension ruins blades and can cause premature failure of bearings in the drive and idler wheels. Cutting problems encountered with the band saw are similar to those of the reciprocating hack saw. Most problems are caused by poor machine condition. They can be kept to a minimum if a maintenance program is followed on a regular basis.

12.4.2 Crooked Cutting

This problem is usually the result of a worn blade. Remember to reverse the work after replacing a blade, and start a new cut on the opposite side. See Figure 12-15. A loose blade or a blade rubbing on a clamping fixture will cause the same problem. It can also be caused by excessive blade pressure on the work or by worn saw guides.

Figure 12-10. Band sawing machines. ATypical band cutoff saw with built-in coolant system, manually controlled blade tension, and automatic end-of-cut shutoff. BBand cutoff machines are also available with tilting frame. The frame is capable of tilting up to 45. (W. F. Wells)

Raker

Wavy

Figure 12-12. Saw blades commonly have raker or wavy teeth. Raker teeth are preferred for general use, cutting large solid sections, and cutting thick plate.

12.4.3 Blade Pin Holes Breaking Out

This reciprocating blade problem can be caused by dirty mounting plates or too much tension on the blade. Worn mounting plates can cause a blade to twist and strain in such a way that the pin hole will break out.

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Partial cut made by worn blade

Cut with worn blade

Figure 12-15. Never attempt to start a new blade in a cut made by a worn blade. Reverse the work and start another cut on the opposite side. Cut through to the old cut.

12.4.4 Premature Blade Tooth Wear

When this problem occurs, the teeth become rounded and dull quickly. Insufficient feed pressure (indicated by light, powdery chips) is one of the major causes of this condition. Excessive pressure (indicated by burned chips) causes the same problem. Insufficient pressure can be corrected by increasing cutting pressure until a full curled chip is produced. If too much pressure is the culprit, reduce feed pressure until a full curled chip is formed. Lack of coolant or a poorly adjusted machine can also cause rapid wear. Correct by following the manufacturers recommendations.
Correct Incorrect

Figure 12-16. Recommended ways to hold sharp-cornered work for cutting. A carefully planned setup will ensure that at least three teeth will be cutting, greatly extending blade life.

12.4.5 Teeth Strip Off

This failure results when the teeth snap off the blade. Starting a cut on a sharp corner is a major cause of this problem. A machine setup with a flat starting surface will greatly reduce tooth stripping. Be sure the work is clamped securely; loose work can also cause the teeth to strip, Figure 12-16. Check the manufacturers chart to determine the proper blade for the job to be done. A blade with teeth too fine will clog (load) and jam, causing the teeth to shear off. A blade that is too coarse (less than three teeth cutting) will cause the same problem. Make sure the blade is properly mounted and cutting on the power stroke.

12.5 CIRCULAR METAL-CUTTING SAWS

Metal-cutting circular saws are found in many areas of metalworking. Primarily production machines, these saws are divided into three classifications: Abrasive cutoff saw. Cold circular saw. Friction saw.

An abrasive cutoff saw, Figure 12-17, cuts material using a rapidly revolving, thin abrasive wheel. Most materialsglass, ceramics, and metalscan be cut to close tolerances. Hardened steel does not require annealing to be cut. Special heat-resistant abrasive wheels are available for high-speed cutoff of hot stock. Abrasive cutting falls into two classifications, dry and wet. Wet abrasive cutting, while not quite as rapid as dry cutting in some applications, produces a finer surface finish and permits cutting to close tolerances. The cuts are burn-free and have few or no burrs. Dry abrasive cutting does not use a coolant and is used for rapid, less-critical cutting. A cold circular saw, Figure 12-18, makes use of a circular, toothed blade capable of producing very accurate cuts. Large cold circular saws can sever round metal stock up to 27 (675 mm) in diameter. A friction saw blade may or may not have teeth. The saw operates at very high speeds (20,000 surface feet per minute or 6000 m per minute) and actually melts its way through the metal. Teeth are used primarily to carry oxygen to the cutting area. These machines find many applications in steel mills to cut red-hot billets (sections of semifinished steel).

Figure 12-17. An industrial abrasive cutoff saw. (Everett Industries, Inc.)

12.6 POWER SAW SAFETY

Never attempt to operate a sawing machine while your senses are impaired by medication or other substances.

Get help when you are lifting and cutting heavy material. Clean oil, grease, and coolant from the floor around the work area. Burrs on cut pieces are sharp. Use special care when handling pieces with burrs. Follow the manufacturers instructions for tensioning a blade. Too much tension can shatter the blade. Handle band saw blades with extreme care. They are long and springy and can uncoil suddenly. Be sure the work is mounted solidly before starting a cut. Be sure all guards are in place before using the saw. Always wear a dust mask and full face shield when cutting stock with a dry-type abrasive cutoff saw. Avoid standing directly in line with the blade when operating a circular cutoff saw. Use a brush to clean chips from the machine. Do not use your hands. Wait for the machine to come to a complete stop before cleaning.

B
Figure 12-18. Cold circular saws. AThis automated cold circular saw can accept a piece up to 2500 pounds. A laser guide light marks the position of the cut. BThis machine can be fitted with carbide-tipped blades or abrasive disks. (W.J. Savage Co.)

Keep your hands out of the way of moving parts. Stop the machine before making adjustments. Have all cuts, bruises, and scratches, even minor ones, treated immediately.

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TEST YOUR KNOWLEDGE

Please do not write in the text. Write your answers on a separate sheet of paper. 1. List the three basic types of metal-cutting saws. 2. The _____ type saw has a back-and-forth cutting action. However, it only cuts on the _____ stroke. 3. What is the three-tooth rule for sawing? 4. When using a power sawing machine, with which materials should you not use coolant? 5. Hacksaw blades are manufactured in two principal types. Name them. 6. The following rule-of-thumb should be followed for selecting the correct blade: a. _____ teeth per inch for cutting large sections or readily machined materials. b. _____ teeth per inch for cutting harder alloys and miscellaneous cutting. c. _____ teeth per inch for cutting on the majority of light-duty machines, where work is limited to small sections and moderate to light feed pressures.

7. List three methods used to put proper tension on a power hacksaw blade. 8. When is a stop gage used? 9. What three advantages does the continuous band sawing machine offer over other types of power saws? 10. Band saw blades are made with two types of teeth. Name them. 11. The tooth pattern of a blade determines the efficiency of a blade in various materials. a. The _____ tooth is best suited for cutting most ferrous metals. b. The _____ tooth pattern is preferred for cutting aluminum, magnesium, copper, and soft brass. c. The _____ tooth is also recommended for most nonferrous metallic materials. 12. List the three types of circular metal-cutting saws. 13. List five safety precautions to be observed when operating a power saw.

Grooving and parting are operations frequently performed on the lathe. This grooving tool uses a replaceable insert that clamps into a special thin holder for performing deep face grooving. The insert can be reversed, allowing a quick change to a new cutting edge when one becomes dull or damaged. Inserts for grooves ranging from 2 mm to 6 mm in width are available. (Iscar Metals, Inc.)