Benefits of Industrial Horizontal Bandsaws

Benefits of Industrial Horizontal Bandsaws

Two types of saws can be used to cut metals with ease – electric hacksaws and bandsaws. Electric hacksaws mimic the back-and-forth motion of a regular hacksaw, using two pulleys to cut large-diameter metals into square or angled shapes. Bandsaws, on the other hand, excel at making continuous cuts and are classified into two main categories: vertical bandsaws and horizontal bandsaws. Vertical bandsaws are only suitable for soft metals, while horizontal bandsaws utilize long-toothed blades to easily cut through hard and thick metals, such as steel. As a result, horizontal bandsaws are widely used for metal cutting in a variety of industrial applications.

We will explore the different benefits of using industrial horizontal bandsaws to cut high-strength and difficult-to-cut metals.

 

Challenges of Processing High-Strength Metals

High-strength metals, such as titanium, steel, and aluminum, are highly sought after in many industries for their durability and excellent corrosion resistance in harsh environments. However, these metals also share some common difficult-to-machine properties, such as:

Low thermal conductivity, which results in extremely high tool temperatures during cutting operations

A tendency to work harden, where the metal softens and sticks to the cutting tool

Low Young's modulus, which results in a poor surface finish

Thus, you must carefully select the right tool to cut these metals to size. A dull tool will heat up quickly due to the high temperatures generated by friction, which can shorten tool life and reduce surface finish quality. To ensure the best surface finish, feed rates must be kept as high as possible. In addition, the process requires the delivery of high-pressure coolant to address heat issues, remove chips, and extend tool life.

Ideally, you want to ensure low radial engagement to safely cut high-strength metals at high speeds while controlling tool temperatures. Otherwise, the process may face unnecessary challenges such as thermal cracking, distortion, and crater wear.

 

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Advantages of Using an Industrial Horizontal Band Saw

As the name implies, a horizontal band saw moves on a horizontal plane and cuts objects vertically downward at a fixed angle. It features a spring-loaded counterweight and sliding weights to adjust blade pressure.

 

The advantages of using a horizontal band saw for processing high-strength metals include:

Precision Cutting
An ideal horizontal band saw is equipped with a built-in rotating quick clamp that allows metal to be cut at angles ranging from 0° to 60°. Selecting the right blade ensures uniform chip production at a consistent rate. Additionally, a hydraulic feed mechanism helps clear chips at an optimal feed rate, preventing clogging of the band saw.

Fast Cutting
Compared to jigsaws, horizontal band saws can cut metal significantly faster-up to a hundred feet per minute for steel. Furthermore, you can switch between minimum and maximum blade speeds to optimize production without compromising blade life.

Ease of Use
Industrial horizontal band saws come in various designs, including semi-automatic and fully automatic models, to maximize operator control. For example, the blade can be fed into the material manually or via a spring-assisted twist system for hands-free feeding. This provides added protection for the operator and helps prevent operational hazards caused by human error.

 

Minimizes Production Waste
Horizontal band saws use narrower blades than chainsaws or table saws, resulting in a smaller kerf and reduced material waste. You can also reset the vise to clamp additional metal stock without repositioning, allowing for precise cutting angles in a single operation. This further reduces metal waste and facilitates a quicker turnaround.

When operating a band saw machine, it is important to follow minimum PPE and safety requirements to ensure safe operation. Adhering to proper band saw safety procedures can help prevent common workplace injuries such as cuts, abrasions, and repetitive strain injuries. If you lack the necessary infrastructure or expertise to operate a band saw, consider hiring a professional metal supplier to perform the cutting for you.