Ever wondered how the metal components are so precisely shaped and how they are uniformly designed to fit different products? Well, the metal cutting band saw machine is the secret behind it. It is much in demand by many manufacturers due to its accuracy and efficiency. The sharp blades of this metal can cut through various metals with ease. However, just like any powerful machine, this machine also needs to be handled with caution so that the cutting operations are perfect. The improper usage of the machine can lead to tool damage, inaccurate cuts, and safety hazards. So, if you are a beginner or an experienced machine operator, understanding how the machine functions is essential. The machine enhances the quality of your operations if it is handled right. So, here are some of the mistakes that you should avoid.

• Using the Wrong Blade:

The machine will function well when it has the right components attached to it, including the blade. Each of the blades has a different thickness and quality. All the blades cannot precisely provide output for different metals. The wrong tooth configuration of tooth on blades can damage the metal and even the components of the machine. The fix for this mistake is to choose the blade as per TPI (teeth per inch), depending on the metal, like aluminum or hardened steel. The thickness of the metal is also vital to be considered. 

• For harder metals, go for fine fine-tooth blade (14-21 TPI).

• For softer metals, a coarse tooth blade (6-10 TPI)  is apt.

• If you are looking for sturdy, quality, and durable ones, choose the bi-blades. They are versatile and can be used for a wide range of metals.

• Incorrect Feeding Rate:

The feeding strategy also matters. If the raw material is fed either too fast or too slow, it will lead to heat buildup. If the pressure is too high during the operations, it will cause uneven cuts. To ensure that the cuts are fine, match the feeding speed and cutting speed. Also, go through the manufacturer’s instructions and set the settings for operations accordingly for optimal performance. Not just that, you also need to be patient. Do not apply extra pressure on the blade; allow it to function at its own pace. The output will be precise. 

• Not Installing the Blade Correctly:

If the blade is too loose, it can slip off during the operations and lead to mishaps. On the other hand, if it is too tight, it can damage the machine components. So, if you are unsure about how to install the blade, it is best to first read the manufacturer’s instructions. It will guide you on how to install the blade properly without any professional help. You can try the tension gauge test for the ‘blade flick test’ - which will guarantee whether the blade tension is precise. If it is so, the test will lead to the production of a high-pitched ‘ping’. You need to keep doing this test regularly to ensure that the blade is in good condition and will provide precise operations. 

•  Ignoring Lubrication:

Lubrication is essential due to the high stress on the moving parts of the machine. If the band saw is not lubricated and it runs dry, it can end with an overheated blade and other components. It can also impact the efficiency of the operations. So, always use the right lubricant for the machine. You can also ask for advice from the manufacturers, and they will be able to provide you with the best lubricator options. 

• For cutting non-ferrous metal(aluminum or brass), choose the oil-based lubricant. 

• For ferrous metals like iron and steel, the water-soluble lubricants are best. 

• Keep the coolant system clean and maintain a proper flow. 

• Not Securing the Workpiece:

One of the major things that leads to precise cutting of metal is firstly fixing the work properly in its place and making it stable. If the workpiece is left loose, it will continuously move during the operations, which will impact the precision, but also increase the chances of accidents. So, before starting the operations, always use the clamp. Also, make sure that the workpiece is well-supported and has actual support, especially if it is long and heavy. 

Conclusion…

The metal cutting band saw machine is a precise tool and a silent hero in the metal industry. However, you just need to use it the right way. You should not commit the above-mentioned mistakes. Just follow the fixes mentioned, and it will enhance the durability of the blade of the machine. It will also increase the safety for the workers and reduce the operational costs. ‘Surya Machine Tools’ has a dedicated team of engineers who manufacture high-quality machines which are sturdy construction and efficient operations. The advanced technology of the machine increases the output. So, if you want effective metal fabrication, then you should invest in one of these machines for sure.

Frequently Asked Questions:

1. How Does the Metal Cutting Band Saw Machine Work?

It is a heavy-duty machine that consists of a powerful blade, and it has sharp teeth. It rotates at high speed continuously when switched on, which leads to precise cutting through various metals. 

      2. How to Pick the Right Blade for Cutting Metal?

Here are the tips that you should keep in mind:

• Teeth per Inch (TPI): 

The coarse of (6-10 tpi) is apt for soft metals. The fine (14-24 tpi) for hard or thin metals. 

• Blade Material:

The bi-metal blades are apt for areas which has high and fluctuating temperatures. These blades are sturdy and have heat resistance.

• Width & Thickness:

Choose based on their saw type and the desired cut for precision.

      3. What are the Maintenance Tips for a Metal Cutting Blade Band Saw Machine?

• Cleaning chips and debris after use

• Checking & adjusting the blade

• Lubricating the moving parts

• Ensuring the cleanliness of the coolants

• Inspecting the blade for wear and cracks

• Checking and replacing the worn-out bearing and belts