The last big leap in the band saw blade manufacturing process took place in the mid-1960s, when bimetallic saw blades were approved and carbide saw blades followed.
The band saw has a limited sawing efficiency before the bi-metal saw blade. In the past, band saw blades were made of high carbon steel because they were flexible enough to withstand the stress caused by the sawing wheel and the blade guide due to the curved path of the saw blade. Bi-metal saw blades require the use of relatively flexible substrates, which has become a barrier for manufacturers to improve sawing efficiency by increasing material hardness and extending tooth life.
Bi-metal and carbide band saw blades have revolutionized the sawing process permanently. Since then, in addition to the improved hard-tooth welding method, the development of sawtooth structures, tooth profiles, blade materials and steel backs has enabled band saw blades to be compared. The steady pace is moving in the direction of increasing productivity and saw blade life.
Like the advent of bimetal and carbide saw blades, the latest developments in second-generation PVD coatings and sawtooth designs have become the latest leap in band saw cutting.
Second generation coating
After years of application to small tools such as drills, inserts, end mills, etc., the coatings began to appear in the band saw blade manufacturing industry in the early 1990s, with mixed results, because the earliest monolithic titanium nitride (TiN) coating Layer saw blades are not only expensive, but also plagued by inconsistent manufacturing quality. Today, second-generation coatings allow for higher sawing and feed rates and increased excessive friction and heat generation of the saw blade due to the increased toughness of the saw blade. The protective film coated on the band saw blade can significantly improve production efficiency without reducing the service life of the saw blade. These coatings are the next major improvements in the band saw market: coated carbide saw blades for increased feed rates and bimetallic saw blades for improved saw blade life.
In the past few years, saw blade manufacturers have gradually mastered the various coating processes (chemistry, material preparation, coating techniques and fixtures) required for large tools such as band saw blades, and the band saw blades produced by the improved coating process are increasingly Welcomed by the factory, especially high-yield processing plants.
Manufacturers now produce a variety of advanced, purpose-specific (such as titanium nitride (TiN) and titanium aluminum nitride (AlTiN)) coated saw blades that provide unprecedented productivity and increase lifetime. The coated bi-metal saw blade combines the benefits of bimetal and protective coating to ensure high sawing speed and feed rate in addition to increased saw blade life.
Currently, band saw blade manufacturers are developing future coatings, including nanocomposite third generation PVD coatings.
Tooth shape design is becoming more and more important
Manufacturers have been steadily improving tooth profile for many years. In the mid-1990s, the emergence of design techniques such as 3D machining simulation software accelerated the pace of tooth profile improvement, making field testing possible. Field testing typically takes a long time and is expensive. With these new tools, new methods such as variable tooth height/split form are optimized, allowing many processing plants to get the most out of their band saw investment.
New results show that there are still possibilities for major breakthroughs in tooth design, such as the recently recommended large cross-section profile. This special tooth shape has an enhanced cutting surface to avoid broken teeth, prevent premature blade failure, reduce burrs, speed up chip removal, extend life and produce oil-free bearings with little vibration and noise.
We are increasingly recognizing that even the most subtle effective improvements can affect cutting performance, and we can expect other manufacturers to make similar improvements in tooth design.
The band saw has a limited sawing efficiency before the bi-metal saw blade. In the past, band saw blades were made of high carbon steel because they were flexible enough to withstand the stress caused by the sawing wheel and the blade guide due to the curved path of the saw blade. Bi-metal saw blades require the use of relatively flexible substrates, which has become a barrier for manufacturers to improve sawing efficiency by increasing material hardness and extending tooth life.
Bi-metal and carbide band saw blades have revolutionized the sawing process permanently. Since then, in addition to the improved hard-tooth welding method, the development of sawtooth structures, tooth profiles, blade materials and steel backs has enabled band saw blades to be compared. The steady pace is moving in the direction of increasing productivity and saw blade life.
Like the advent of bimetal and carbide saw blades, the latest developments in second-generation PVD coatings and sawtooth designs have become the latest leap in band saw cutting.
Second generation coating
After years of application to small tools such as drills, inserts, end mills, etc., the coatings began to appear in the band saw blade manufacturing industry in the early 1990s, with mixed results, because the earliest monolithic titanium nitride (TiN) coating Layer saw blades are not only expensive, but also plagued by inconsistent manufacturing quality. Today, second-generation coatings allow for higher sawing and feed rates and increased excessive friction and heat generation of the saw blade due to the increased toughness of the saw blade. The protective film coated on the band saw blade can significantly improve production efficiency without reducing the service life of the saw blade. These coatings are the next major improvements in the band saw market: coated carbide saw blades for increased feed rates and bimetallic saw blades for improved saw blade life.
In the past few years, saw blade manufacturers have gradually mastered the various coating processes (chemistry, material preparation, coating techniques and fixtures) required for large tools such as band saw blades, and the band saw blades produced by the improved coating process are increasingly Welcomed by the factory, especially high-yield processing plants.
Manufacturers now produce a variety of advanced, purpose-specific (such as titanium nitride (TiN) and titanium aluminum nitride (AlTiN)) coated saw blades that provide unprecedented productivity and increase lifetime. The coated bi-metal saw blade combines the benefits of bimetal and protective coating to ensure high sawing speed and feed rate in addition to increased saw blade life.
Currently, band saw blade manufacturers are developing future coatings, including nanocomposite third generation PVD coatings.
Tooth shape design is becoming more and more important
Manufacturers have been steadily improving tooth profile for many years. In the mid-1990s, the emergence of design techniques such as 3D machining simulation software accelerated the pace of tooth profile improvement, making field testing possible. Field testing typically takes a long time and is expensive. With these new tools, new methods such as variable tooth height/split form are optimized, allowing many processing plants to get the most out of their band saw investment.
New results show that there are still possibilities for major breakthroughs in tooth design, such as the recently recommended large cross-section profile. This special tooth shape has an enhanced cutting surface to avoid broken teeth, prevent premature blade failure, reduce burrs, speed up chip removal, extend life and produce oil-free bearings with little vibration and noise.
We are increasingly recognizing that even the most subtle effective improvements can affect cutting performance, and we can expect other manufacturers to make similar improvements in tooth design.
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