Multiple factors cause negative issues with cut that affect the quality of the bandsaw machine’s performance and output. The following are some of the possible causes and their solutions to the issues:
Dull blade
It is highly recommended that the saw blade be replaced rather than having it sharpened. To avoid premature dulling of saw blade teeth, proper break-in procedure should be implemented along with things like coolant concentration and flow, the chip brush, appropriate feed rates and blade speed, and a proper tooth pitch for the material being cut.
Improper break-in
New bandsaw blades have sharp teeth that are fragile prior to a light hone. Honing the teeth with a break-in on a light cut will help keep the teeth even, producing a perfectly straight cut afterward.
Guide arms too far apart and/or out of alignment
Guide arms should be as close to the work as possible and firmly secured. Loose side guides allow the blade to lean over. Make adjustments or replace if needed.
Damaged roller and/or carbide guide
Neither damaged rollers nor damaged carbide guides can properly support and align the band. Replace the damaged guides and make the proper adjustments in order to maintain a straight cut.
Feed rate too heavy and/or Blade speed too slow
Too heavy a feed rate and too slow a blade speed will both affect the life of the saw blade. Consult the feed and speed rate chart for the material being cut and set the saw accordingly.
Tooth pitch too fine
Too few teeth can cause them to straddle the work piece. Change to a blade with the proper tooth pitch for the material being cut.
Band tension too low
Too low band tension gives the blade poor beam strength, causing band fatigue and crooked cuts. Apply proper tension to the bandsaw blade.
Vise clamp out of square
If the vise clamp is out of square, consult with the Operator’s Manual and apply the recommended adjustments.
By following these simple remedies, the results will be to achieve the best straight cuts.
Bow-shaped cuts and bad surface finish on work pieces is another negative issue regarding cut that will result in a negative impact on production cost by creating additional work.
Below are the possible causes and their solutions:
Worn or improperly adjusted side guides or guide arms
Adjust, repair, or replace
Blade guides not aligned
Use the dial indicator on the side of the blade to test the alignment
Saw bed or feed table not square
Check the operator’s manual for correct realignment instructions
The fixed vise not square to the blade
Check the operator’s manual for adjustments
Excessive feed pressure
Increase speed or decrease feed
Low band tension
Check the operator’s manual for recommended adjustments
Irregular Cuts will also cause bad surface finishes. For this particular issue, check the following:
Teeth too coarse
Select finer pitch
Band speed too slow
Increase band speed
Feed rate too great
Decrease feed rate
Machine defect
Stop the bandsaw machine and examine all of the components
Lack of coolant
Increase the supply of coolant
Knowledge and experience are key to avoiding these types of problems. In order for good production to be achieved, the potential for problems should be a second-nature awareness with the bandsaw operator, along with the ability to pinpoint the above-mentioned issues before a larger issue can occur.
It is not only the common, easy to identify issues that need attention, but also giving priority to the complex issues as well. Avoidance is key to achieving a successful cut.
