Attaching the Band Saw to the Bench and Practice Instructions

Band saws are structurally composed of spring steel body and 67-68 HRc hardness M42 (1.3247) or 70 HRc hardness M51 high speed steel (Bimetal structure). Unless training is done on such a hard cutting edge, the band Blunting and smearing occur in a short period of time, total cutting amounts decrease, and problems may occur with the desired surface quality or measurement tolerances.

  1. The first thing to do when installing a new strip on the band saw machine is to activate the Emergency button or completely disconnect the machine's electricity from the outlet before opening the pulley covers.
  2. The band saw's pulley contact points, feed path and carbide holder bearings must be completely cleaned with compressed air.
  3. The band saw should always be attached to the pulley surfaces together with the existing wick, and gloves should be used during these operations. (The purpose of installing the band saw with the wick on it is to prevent the hard strip ends from damaging the machine body or human hands, and to eliminate possible breakages at the ends.)
  4. While the band saw is placed on the pulleys, the back part of the band saw must be placed on the pulley ribs, and the rear end of the band saw must fully press on the back bearings in the carbide holder bearings on both sides at the same rate. (If there is any channel formation or error, especially in the back bearings, please renew them.)
  5. After the band saw is correctly placed on the pulley and carbide holder bearings, the band saw slack should be taken from the hydromechanical tension arm or hydraulic band tensioner. Robert Röntgen band saws are set with a tension force of 250-300 N/mm². The correct tension significantly affects the cutting accuracy of the blade, and if the blades are manually tensioned on saw machines, the tension intervals recommended by the machine manufacturers should be checked and corrected if necessary. (Please see FOOTNOTE 1.)
  6. After the necessary tensioning process is completed, the first step to be taken in the strip lapping process is to run the saw with the cooling water completely open (in contact with the saw surface) and the strip speed at the highest level for at least 5-7 minutes, without touching the part. operating at idle.
  7. After the first idle operation, the distance between the back of the band saw and the pulley bill should be checked. At this point, the pulley angles should be approximately 1-1.5 mm apart on a healthy bench, otherwise cracks will occur on the back of the band saw and breakages and ruptures will occur. (If the gap between the pulley invoice and the band saw is outside the specified size range, please check the pulley angles.)
  8. Sonrasında şerit dönüş hızını kesilecek malzeme grubuna göre ortalama %60 oranında düşürüp (Her bir malzeme grubunun ilerleme ve testere dönüş oranları farklıdır, bu konuda malzeme bazlı olarak bizden destek alabilirsiniz) malzeme üzerinden görece talaş kaldıracak şekilde testereyi malzemeye temas ettirmek ve bu şekilde 2-3 dk. kadar ilerleme vermeden malzeme yüzeyinde tıraşlama yapması gerekmektedir.
  9. Bir sonraki adım olarak ilerleme miktarı malzeme grubuna göre yine yaklaşık %50 oranında düşürülüp (Burada hız-ilerleme dengesi doğru bir şekilde sağlanmalıdır, Ses ve vibrasyon burada en önemli 2 faktör olup şerit testereden yüksek mekanik bir ses geliyorsa şerit hızı potansiyometreden mevcut ses kesilene kadar kademe kademe kısılmalıdır.) ve toplamda 0.060-0.070 m2 bir yüzey alan kesilmelidir. (Örneğin 300-350 mm’lik dolu silindirik bir malzemenin tek seferde kesilmesi alıştırma işlemi için yeterlidir)
  10. Finally, if there is a decrease in the strip tension, it should be completed to the required tension without using an additional apparatus and the normal feed amount and strip rotation speed parameters appropriate to the material properties and structure should be changed. (Please see FOOTNOTE 2.)

FOOTNOTE 1: When performing the strip lapping process on benches with a hydromechanical strip tensioning system, the strip tensioner should be tightened gradually (over 2 or 3 cuts) and no pressure should be applied to the strip tensioner arm with an extra part or apparatus. For example, when a new strip is installed, 200 bar should not be applied directly to the 150-200 bar value next to the strip tensioning arm on the machine (This value is specified by the strip loom manufacturer). Tightening should be done gradually. (This operation is not performed in systems with hydraulic strip tensioning system as there will be no pressure loss)

FOOTNOTE 2: When the band saw is not being used or at the end of the working hours, the tension rate should be reduced to the extent that the band saw will not be thrown off the pulley, and the band tension should be re-tightened at the beginning of the working day. In systems with a hydraulic strip tensioning system, this can be easily done with the help of a button or a lever on the tensioning mechanism. The purpose here is to prevent cracks and errors that may occur under tension due to stress stresses that will occur as a result of chip removal in the band saw.

These processes are ABSOLUTELY REQUIRED for saw strength, surface quality and linear healthy cuts.