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SAWING

Sawing is a manufacturing process that uses a saw blade with teeth to cut materials into pieces or remove unwanted sections. Key characteristics of saw blades include rake angles, width, set, kerf, and pitch, with various materials like carbon steel and tungsten carbide-tipped blades available for different applications. Tool failure can occur due to improper blade selection, mounting issues, or excessive cutting forces, and preventive measures include careful blade handling and appropriate cutting speeds.

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9 views4 pages

SAWING

Sawing is a manufacturing process that uses a saw blade with teeth to cut materials into pieces or remove unwanted sections. Key characteristics of saw blades include rake angles, width, set, kerf, and pitch, with various materials like carbon steel and tungsten carbide-tipped blades available for different applications. Tool failure can occur due to improper blade selection, mounting issues, or excessive cutting forces, and preventive measures include careful blade handling and appropriate cutting speeds.

Uploaded by

dinesh.amudesan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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SAWING

Sawing is a process wherein a narrow slit is cut into the work piece by a tool consisting
of a series of narrowly spaced teeth, called a saw blade. Sawing is used to separate work parts
into two or more pieces, or to cut off an unwanted section of a part. These processes are often
called cut-off operations and since many manufacturing projects require cut-off operations at
some point in the production sequence, sawing is an important manufacturing process.
As the blade moves pass the work, each tooth takes a cut. Depending on the thickness or
diameter of the work, the number of teeth cutting at one time varies from two to ten or more.
Saws may be of the continuous cutting (band or rotary) or reciprocating type.

CHARACTERISTICS AND TERMINOLOGY


RAKE ANGLES - Rake angles are 0 degrees or neutral rake on most saw blades. Some have a
positive rake angle.
WIDTH - The width of a saw blade is its total width, including the teeth.
SET - The set of a saw blade means the offsetting of some teeth so that the back of the blade
clears the cut. The "raker" set is most frequently used and is furnished with all hacksaws and
band saws unless otherwise specified.
KERF - The kerf is the width of the cut made by the saw blade or the material cut away. The
thickness of the blade is called the gage.
PITCH - The pitch of a saw blade is the distance between the tops of two adjacent teeth. This is
specified in teeth per inch.

SAW BLADE MATERIAL


Carbon steel - General utility for small lot, low-speed work. The least expensive blade, these
may have a hard "back" for greater wear.
High-speed steel (HSS) - This costs two to three times as much as carbon steel, but it is much
longer wearing and is a necessity for the "difficult-to-machine" metals.
High-speed edge - This is a carbon steel blade, which has a narrow strip with HSS teeth welded
on. This is a tough blade, intermediately priced, and widely used for most materials.
Tungsten carbide-tipped blades - Available in a few sizes. Used only on large, very rigid
sawing machines for high-production sawing of difficult materials.

CUTTING SPEED OF SAW


Cutting speed for sawing is determined by the same considerations as for any other
machining operation. Normally power driven hack saws are equipped with 3 or 5 speeds in their
working mechanism. The speed of a saw is expressed as number of strokes per minute with
high carbon steel blade, the higher speed should be used in cutting mild steel and other soft
materials with HSS blade all materials can be processed at appreciable higher speeds. The
cutting speed can also express as meter per second (mps). In this expression length of a blade
also matters a log along with number of strokes per unit time.

TOOL FAILURE AND PREVENTIVE MEASURE


1. Erratic cutting or no cutting from beginning of the operation. During loading of the
blade to the saw teeth may point in wrong direction. It should be reversed teeth
pointing towards the crank.
2. Selection of a wrong blade leads to its poor performance like poor life of blade,
excessive wear, and poor quality of cut. The blade should be selected by considering
size, number of teeth, suitable material (its properties) in according to the work piece.
3. Unexpected breakage of the blade. It may be due loose mounting of blade, work piece
or both. Clamping should be checked.
4. Unexpected breakage may also be due to improper tension in blade. Proper tightening
without buckling of blade should be ensured.
5. For longer life of the blade, it should not be left under tension while not in use.
6. Start of cut should be done slowly so that blade can be accommodating into the
groove of the cut made on the work piece. This will avoid risk of slip and breakage.
7. If a blade breaks during the process, the unfinished cut should not be processes using
a new blade. The main reason for that is new blade is always considered thicker than
the used/old blade.
8. To cut the thicker sections low speeds and very small feed rate should be maintained
to avoid breakage of the blade.

TOOL LIFE
Three modes of failure,
1. Fracture failure - Cutting force becomes excessive and/or dynamic, leading to brittle
fracture
2. Thermal failure - Cutting temperature is too high for the tool material
3. Gradual failure - Gradual wear is preferred because it leads to the longest possible use of
the tool
– Flank wear - flank (side of tool)
– Crater wear - top rake face
– Notch wear
– Nose radius wear
TAYLOR TOOL LIFE EQUATION
Where v = cutting speed; T = tool life; and n and C are parameters that depend on feed,
depth of cut, work material, tooling material, and the tool life criterion used
n is the slope of the plot
C is the intercept on the speed axis

vT n =C
CALCULATION OF CUTTING SPEED, SPINDLE SPEED AND FEED

TOOL LIFE VS CUTTING SPEED


TOOL TIP TEMPERATURE VS CUTTING SPEED

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