December 5, 2015 / blade life, blade selection, Cost Management, cost per cut, LIT, material costs, optimization
Any metal-cutting expert knows that having the right blade for the job is critical. Although it may seem like a small operational detail, blade performance impacts several key business areas, including productivity, maintenance, quality, and tooling costs.
Like any purchasing decision, blade selection needs to be strategic, taking into consideration a host of variables—business goals, material type, equipment, and operator skill level, to name just a few. Blade performance is also based on several variables—the cutting application, blade specification, number of teeth per inch, tooth set, etc. Put simply, not every blade is created equal, and choosing the wrong blade can result in poor quality cutting and higher operational costs.
The problem is that many of today’s service centers don’t even realize they are using the “wrong” blade. In many cases, companies settle for “good” instead of “great.” Managers and operators become content with the blade technology they’ve been using for years and end up missing out on the benefits a new blade technology could bring to their operation.
This is a common occurrence in band sawing. For example, many service centers have used bi-metal band saw blades over the years and have had decent results. And in many cases, bi-metal blades are a good choice. However, there are applications in which carbide blade technology would be the better choice.
Many companies are finding that making the switch to carbide blade technology can provide savings and productivity gains they would never have achieved with bi-metal blades. This was the case for Aerodyne Alloys, a metal service center featured here in Today’s Energy Solutions. For years, the company’s Greenville, South Carolina facility used bi-metal blades to cut its toughest metals, including stainless steel, nickel alloy, and super-alloys like Inconel 718 and Hastelloy.
To gain more performance out of its band saws, Aerodyne decided to upgrade to carbide blades. Carbide-tipped band saw blades use strong, durable materials to provide high performance, faster cutting, and prolonged blade life. The blade tooth has carbide tips welded to a high-strength alloy backing, allowing the metal service center to take on hard, nickel-based alloys, as well as stainless steel, tool steel, and titanium.
In addition to tackling hard-to-cut metals, carbide-tipped band saw blades offer longer blade life and faster cutting. The white paper, Characteristics of a Carbide-Friendly Band Saw Machine, further elaborates the benefits of the carbide technology by providing a real-life comparison between a bi-metal blade and a carbide-tipped blade. The test produced the following results:
- The bi-metal band saw blade (LENOX Contestor GT) ran 120 feet per minute with a feed rate of 0.53 inches per minute.
- The carbide blade (LENOX Armor CT Black) ran at 320 fpm with a feed rate of 3.11 inches per minute.
Ultimately, the higher speed and feed rate of the carbide blade enabled it to make the cut 13 minutes faster, translating into 160 more parts produced during an 8-hour shift than its bi-metal counterpart.
Carbide-tipped band saw blades can also deliver benefits to a metalworking operation by producing an improved surface finish. In many cases, a cut part will require additional processing steps downstream in order to refine the finish. By having a smoother finish, the carbide blade can reduce the number of secondary processes, which saves both time and money.
A good example of this is LENOX’s new carbide blade technology, which was featured in the latest issue of Modern Metals. Developed to cut aluminum and nonferrous alloys, the carbide-tipped band saw blade is able to make straight cuts at high speeds without sacrificing surface finish. As stated in the article, the blade tip’s particular grade of carbide wears very slowly, which is ideal for cutting aluminum. A multi-chip tooth pattern balances the chip load and reduces cutting forces, and sharp-edged teeth and high rake angles penetrate material more easily. The cutting tool is said to be the latest blade designed specifically to cut aluminum and nonferrous parts often used in today’s aerospace and automotive applications.
As carbide blade technology continues to advance, the more options service centers have to optimize and grow their operations. Whether the goal is to take on a harder material, improve performance, or increase quality, carbide-tipped blades are an investment worth considering. While the upfront product cost may be higher than other blade types, benefits like improved productivity, lower operational costs, and higher customer satisfaction will pay off in the long run.
For more information on the benefits of carbide blade technology, click here to download the white paper, “Leveraging Carbide Blade Technology to Increase the Productivity of Your Sawing Operation.”