Thông qua sự hiểu biết toàn diện về cơ học cưa và các vấn đề cụ thể phát sinh khi cưa phôi hình ống, nhiều vấn đề trong đường ống và cắt ống có thể được giải quyết. Loại bỏ các vấn đề khi cưa giúp trong ba lĩnh vực: tăng tốc độ cắt, kéo dài tuổi thọ của lưỡi cưa và tối ưu hóa chất lượng cắt.

When cutting hollow workpieces, the blade will interrupt the cutting. It enters and leaves one side of the material, and then enters and leaves the other side. This puts extra force and stress on each tooth compared to cutting a solid workpiece. When one saw tooth touches the cutting tooth and the next saw tooth enters the cutting tooth, the force is so great that it actually breaks a saw tooth. After the stress causes the serrations to chip or completely tear the serrations, the force on the remaining serrations will be even greater, which may cause premature failure of the blade.

The circular workpiece poses a challenge in terms of coolant distribution. The shape of the workpiece will divert the coolant from the cutting, which can cause inaccurate cutting and increase heat build-up. Both of these problems will destroy the jagged edges prematurely.

Khắc phục sự cố cưa như sau

Many traditional bimetal blades also produce a heat-affected zone (HAZ), where the heat increases so much that it changes the characteristics of the steel. Cutting through the heat-affected zone will cause the serrations to tear off the blade. Likewise, if the speed of the blade is too low for the material, the process cannot provide enough penetration for each tooth, causing more friction than cutting. This can also overheat the material.

Another challenge is the incorrect blade spacing, which is the number of teeth per inch. The number of teeth in contact with the workpiece will affect the performance and durability of the saw blade. Too few teeth in contact with work will cause early tooth loss; too many teeth will reduce the speed of the blade and ultimately make the material unable to cut.

A saw blade with a constant pitch will increase harmonic vibration, which can lead to excessive noise, undesirable saw blade or saw blade vibration, and even in severe cases, it can cause cuts. Manufacturers can solve this problem by choosing variable pitch blades, which can greatly reduce harmonic vibration. The change in tooth pitch disrupts the rhythm that causes harmonics and improves chip removal.

Although each band saw blade looks somewhat similar, they are quite different. Blade manufacturers have proposed new concepts in their construction and have incorporated new features over time, allowing the blades to cut faster and have a longer service life.

In the past few decades, the band saw blade is likely to be a single steel strip with serrated teeth, but today, advanced saw blades are more likely to be made of multiple parts. An example is a blade made by a patented process in which two high-speed steel wires are connected to the backing steel. The heat used in the connection process of solid-state diffusion bonding is about 20% of the conventional welding process, which is 170% larger than the welding contact area produced by the conventional process. The result is that the possibility of fracture and cracking at the interface of the two materials is greatly reduced.

Soon after the first use, the blade made by this method formed a 0.001 to 0.002 inch deep U-shaped groove between the two high-speed steel edges. The cutting action of the serrated geometry produces two chips. Compared with traditional chips, the two chips are easier to remove, so the possibility of welding to the saw teeth is less. The groove also allows increased coolant flow to the cutting surface. The proper coolant flow can cool and lubricate the blades and flush away the chips.

Hướng dẫn khắc phục sự cố

1. The blade is broken:

Wrong blade selected-choose a blade with the right pitch for the application.

Saw blade tension setting is incorrect-adjust the saw blade tension according to the saw manufacturer’s instructions.

The feed pressure is set too high-reduce the pressure accordingly.

Insufficient lubrication-confirm that the lubricant is matched to the application and mixed in the proper ratio. If necessary, adjust the lubricant nozzle to improve the lubricant flow.

The pressure block is set too tight-adjust the guide.

The blade rubs on the rim-adjust the center of the wheel.

Insufficient blade holder-tighten, align, adjust or replace the guide plate.

The side guides are set too tightly-adjust the side guides.

2. Premature wear of saw teeth:

Install the blade backwards-install the blade correctly.

Incorrect blade insertion procedure-use the insertion procedure recommended by the blade manufacturer.

The material is too hard or the surface scales are too thick-choose a blade suitable for the material.

The material is too hard-increase the feed pressure.

Insufficient lubrication-confirm that the lubricant is matched to the application and mixed in the proper ratio. If necessary, adjust the lubricant nozzle to improve the lubricant flow.

The blade speed or feed pressure is set too high-adjust the setting according to the manufacturer’s recommendations.

3. Serrated cutting:

Insufficient blade holder-tighten, align, adjust or replace the guide plate.

Worn blade-replace the blade.

Incorrect feed pressure setting-adjust according to manufacturer’s recommendations.

The tooth pitch in the application is incorrect-choose a blade that meets the blade manufacturer’s recommendations.

Insufficient lubrication-confirm that the lubricant is matched to the application and mixed in the proper ratio. If necessary, adjust the lubricant nozzle to improve the lubricant flow.

Insufficient blade holder-tighten, align, adjust or replace the guide plate.

4. Wandering and cutting:

The feed pressure is set too high-adjust according to the manufacturer’s recommendations.

Blade tension is too low-increase the tension as recommended by the manufacturer.

Damaged serrations-replace the blade and confirm that it matches the hardness of the material.

Insufficient blade holder-tighten, align, adjust or replace the guide plate.

Chips accumulate in the blade teeth

Worn or missing bristles-adjust or replace.

Insufficient lubrication-confirm that the lubricant is matched to the application and mixed in the proper ratio. If necessary, adjust the lubricant nozzle to improve the lubricant flow.

The blade speed or feed pressure is set too high-adjust the setting according to the blade manufacturer’s recommendations.

Wrong blade selected-choose a blade with the right pitch for the application.

5. The blade is only worn on one side:

Worn wheel flange-adjust or replace the wheel.

Worn or misaligned blade guide-adjust or replace.

The tooth is chipped and embedded in the workpiece-replace the blade and use the run-in procedure recommended by the blade manufacturer.

6. Broken tooth:

Incorrect blade insertion procedure-use the insertion procedure recommended by the blade manufacturer.

The blade speed is set too low-adjust the speed according to the manufacturer’s recommendations.

The feed pressure setting is too high-adjust the setting according to the manufacturer’s recommendations.

The incisor is stuck-increase the blade speed and reduce the feed pressure.

Insufficient lubrication-confirm that the lubricant is matched to the application and mixed in the proper ratio. If necessary, adjust the lubricant nozzle to improve the lubricant flow.

The material is too hard or the surface scales are too thick-choose a blade suitable for the material.

Wrong blade selected-choose a blade with the right pitch for the application.

Workpiece rotation-tighten the vise, if you want to cut the bale, use the bale clamp.

7. Worn or damaged blade backing:

The preload of the spare rail is too large-adjust the pressure block according to the manufacturer’s recommendations.

Saw blade tension setting is incorrect-adjust the saw blade tension according to the saw manufacturer’s instructions.

Worn blade-replace the blade.

The blade speed or feed pressure is set too high-adjust the setting according to the blade manufacturer’s recommendations.

8. Distorted cutting edge:

The feed pressure is set too high, causing the saw blade to stick-adjust the pressure according to the saw manufacturer’s instructions.

Insufficient blade holder-tighten, align, adjust or replace the guide plate.

Workpiece is not aligned-tighten the vise.

Finally, saw operators should rely on their own cutting experience to prevent small saw problems from turning into big saw problems. In addition to finding clues, listening to clues can also be of great help. If the cut sounds incorrect, there is a problem, and troubleshooting should begin as soon as possible, not later.

Liên kết đến bài viết này : Troubleshoot the sawing problem as follows

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Khắc phục sự cố cưa như sauĐộ chính xác 3, 4 và 5 trục Cơ khí CNC dịch vụ cho gia công nhôm, berili, thép cacbon, magiê, gia công titan, Inconel, bạch kim, siêu hợp kim, axetal, polycarbonate, sợi thủy tinh, than chì và gỗ. Có khả năng gia công các bộ phận có đường kính lên đến 98 inch. và dung sai độ thẳng +/- 0.001 in. Các quy trình bao gồm phay, tiện, khoan, doa, ren, khai thác, tạo hình, khía, gia công phản lực, gia công kim loại, doa và cắt laser. Các dịch vụ thứ cấp như lắp ráp, mài không tâm, xử lý nhiệt, mạ và hàn. Sản xuất nguyên mẫu và số lượng thấp đến cao được cung cấp với số lượng tối đa 50,000 chiếc. Thích hợp cho năng lượng chất lỏng, khí nén, thủy lực và van các ứng dụng. Phục vụ các ngành công nghiệp hàng không vũ trụ, máy bay, quân sự, y tế và quốc phòng. [email protected] ) trực tiếp cho dự án mới của bạn.

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