Manufacturing
process
190220119007
CHAUDHARI PRANAY VELJIBHAI
TOPIC:- METAL SAWING
Content
Introduction
Applications
Characteristics of metal cutting saw blades
Sawing spees and feeds
Sawing operations and machines
Friction sawing
Introduction
Sawing is an important first operation in any shop for subsequent
machining operations.
Metal and other materials are often cut using sawing machines or hand
saws.
Sawing is used because of some of its characteristic advantages like high
speed of cutting, low wastage of material and low power consumption.
The process can also be easily automated leading to considerable saving
in labour cost.
In the sawing operation a large number of teeth move through the work
piece each successive tooth deepening the cut made by its predecessor
fig..
Feed may be given either to the saw or the job.
Both straight or curved profiles may be cut by controlling the direction of
feeding.
Applications
Sawing is an important first operation in any shop for subsequent
machining operations.
Metal and other materials are often cut using sawing machines or hand
saws.
Diamond teeth blades are used for machining ceramics and other harder
materials.
Power hack saw is a simple machine which can accommodate jobs of
different shapes and sizes.
The straight tooth form is used for band saws used for cutting ferrous
metals but for sawing aluminium,lead alloys and other softer materials
skip tooth or buttress type of tooth profile is preferred.
Some thermoplastic plastics can also be easily friction sawed.
Sawing speeds and feeds
The cutting speed for sawing is determined essentially the same
considerations as for any other operation.
For common metals the speed may vary from 0.2meters per second
for hard and tough alloys to 15meters per second for soft materials.
Feed for sawing is the rate of movement of the saw into the work
piece at high angles to the speed direction and may be expressed in
millimetres per second or millimetres per stroke.
Feed rate determines the depth of cut taken by each individual tooth
and should be so adjusted that the force exerted by the work piece on
the saw in the direction of the feed is as high as the blade would
permit without damage.
Mannual sawing is considered inferior from feed point of view because
it is not possible to ensure a definite and uniform rate of feeding in
mannual sawing.
Characteristics of metal cutting
blades
Metal cutting saws are Characterized by
- Material
- Tooth form
- Tooth set
- Tooth spacing
- Size
Material
Most good quality saws are made from high carbon or
high speed steel.
Larger blades may have only the teeth portion made
from high speed steel while the main portion of the
blade may be made of a low cost alloy steel.
Diamond teeth blades are used for machining
ceramics and other harder materials.
Tooth form
The geometry of the teeth is similar to that of the single
point tools.
Two common tooth forms are the straight tooth and the
undercut tooth form shown in fig..
Of these the undercut profile is considered superior
because the cutting teeth are better backed up and
work with a positive rake angle. But this geometry is
more difficult to make on smaller teeth.
The straight tooth form is used for light feeding rates
while the undercut tooth form is more suitable for coarse
feeding.
Tooth set
Saw teeth are given an offset to the side known as set to produce cuts which are
teeth wider than the thickness of the back of the blade or disk. This is done by
bending some teeth slightly to the right or left.
This enables the saw to move freely without friction.
The three common types of saw tooth sets are shown in fig..
1. A straight set has one tooth set to the right and the next to the left. Saws with
this type of set are used for cutting brass, copper and plastics.
2. In a raker set one straight tooth is followed by two teeth set in opposite
directions. This set is used for most steel and cast iron cutting.
3. A wavy set comprises of an alternate arrangement of several teeth set to the
right and several teeth set to the left. This arrangement is used for cutting tubes
and thin sheets of metal.
Circular saws are made with alternate high and low teeth with height difference of
0.25 to 0.50mm as shown in fig..
Tooth spacing
Tooth spacing or pitch has a significant influence on the performance
of the saw.
The space between the teeth provides room for chips removed during
the cut.
Coarse pitch is needed for larger cuts and for cutting softer materials
to accommodate the larger chips.
Fine pitchs are recommended for harder materials.
For cuts in thin sections a fine enough pitch should be used so that at
least two and preferably three teeth always contact the work piece to
prevent stripping of the teeth.
In general, the pitch used should be the coarse pitch suitable for the
job.
For band saws the pitch may be as fine as 0.75mm.
For hack saws 1.5mm pitch is also considered fine.
Size
Hack saw blades are straight strips. 1 to 3mm
thick,15mm to 65mm wide and 300 to 1000mm long.
Circular saw discs vary from 1 to 6mm in thickness
and 200 to 1000mm in diameter.
The heavier the cut larger will be blade size in
general.
Band saws run from 1 to 6mm in thickness and 1.5 to
25mm in width.
The narrower bands are used to cut smaller radii.
Classification of Sawing
operations and machines
Reciprocating or power hack sawing
Circular sawing
Band sawing
Reciprocating or power hack
sawing
Power hack sawing
In this sawing work piece is clamped in vise.
Arrangements are provided to vary the length of
stroke per min. and also provide feed control device.
Production hack saws are provided with automatic
feeding, measuring and cutting of series of pieces.
During hack sawing adequate quantity of cutting
fluid applied for better working and shorter and
stronger blades are used for minimize blade
breakage.
Machining rate is low but cost is much less than
compared to others.
It is rough operation and generally used for
machining simple jobs.
Circular sawing
Circular sawing
In circular sawing material is cut by means of a rotating saw as shown in fig..
The saw disc has a large diameter to cut through one or more work pieces
held in the vise.
Saws having blade disc diameters upto 200mm are known as metal slitting
saws while those above 200mm diameter are called cold metal saws.
The saw blade is driven by an electric motor through suitable drive elements.
The work pieces may be held with the help of screw clamps or hydraulically
operated clamping devices may be employed. Feeding may be mannual or by
air or hydraulic pressure.
Trip dogs are provided for adjusting the length of feeding.
Circular sawing machines may be mannual,semi automatic or fully automatic.
The last two types are common in production work.
In semi automatic machines feeding of the stock and
removal of cut pieces is done manually while the other
operations are automatic.
In automatic machines all operations except the
feeding of the bar stock are automatic.
Cutting fluid is provided mainly for lubrication as teeth
have sufficient time for cooling when not cutting.
The length tolerance of the order of 0.075mm are
easily obtained.
Band sawing
Band sawing
A schematic diagram for the band sawing machine is given in fig..
The band is made by welding a flexible thin strip long enough to band over
the wheels.
The upper or the idler wheel can be vertically adjusted to provide proper
tension to the saw band.
The tension provided should neither be too low nor too high.
Insufficient tension leads to wandering of the band while too much tension
results in excessive wear of the wheel tyres.
The lower wheel is driven by a variable speed drive.
The work piece is supported on the table which may be tilted at an angle if
necessary.
Saw guides are provided near the cut area to support the saw on its sides.
The upper saw guide is made adjustable vertically to accommodate jobs of
different thickness.
In simpler machines feed is given manually but power fed band saws are
also available.
A thrust rollar support is provided at the back of the band to resist feeding
thrust.
The straight tooth form is used for band saws used for cutting ferrous
metals but for sawing aluminium, lead alloys and other softer materials skip
tooth or buttress type of tooth profile shown in fig. is preferred.
This profile provides more space for the chips and avoids loading of the
saw.
Saw bands are heat treated to have hard teeth and soft back to permit
bending.
This is accomplished by hardening the entire band and then tempering the
back alone so that the hardness of the saw teeth decreases progressive
towards the back.
Band saw machines are available both for straight line cutting and for
Friction sawing
Burning process by which saw band ( with and
without) saw teeth,is run at high speeds to burn or
melt its way through metal
10,000 to 25,000sf/min
Cannot be used on solid metal
Amount of heat generated
Excellent for cutting structural and honeycombed
parts of machine or stainless steel.
Advantages of friction sawing
Friction sawing is several times faster than
conventional sawing. A 150mm diameter steel piece
can be cut in less than 60 Seconds.
Hardened steel and other steels which cannot be cut
by conventional methods can be cut easily by friction
sawing without annealing.
The forces on the work piece are low and hence work
piece can be easily hand fed.
Limitations of friction sawing
Friction sawing procedure a less accurate Surface and
leaves a heavier burr.
The process is limited to thin ferrous metals and
thermoplastics.
