Blade breakage

Sudden failure of saw blades, due to breakage of teeth (carbide) or breakage of the saw blade itself (HSS) is generally caused by:

1)    Too many teeth on the saw blade for the application

2)    Excessive feed rate

3)    Material movement caused by clamping problems

4)    Incorrect choice of cutting parameters for the application

5)    Incorrect saw blade rotation (reversed)

6)    Material advancement when the saw blade is in the down position

Increase Blade life

A common line of thought is that using higher cutting parameters is synonymous with a reduction in blade life. This is not always the case. Depending on the  machine capabilities, we often experience that carbide tipped saw blades are not pushed hard enough to become fully effective.

Our vast experience with many different sawing machines and applications allows us to get the maximum out of Kinkelder saw blades on different machines. Some examples below: 

Machine Application Saw Blade Parameters Vc
(m/min)
Fz 1/2
(mm/tooth)
Output
(pcs/hr)
Bladelife
(m2)
Rattunde ACS90/2 Ø32x3,7 S355 NBK Champion TH 350 Z120 Normal 220

0,04/0,16

1200 9
Improved 280 0,06/0,24 1800 12

 

Machine Application Saw Blade Parameters Vc
(m/min)
Fz 1/2
(mm/tooth)
Output
(pcs/hr)
Bladelife
(m2)
Bewo FCH90M Ø22x1,2 S275 Power 315x1,8 Z240CB Normal 140

0,04

900 3
Improved 180 0,07 1400 7
Simplify Stock management

- One blade cuts all

By carefully analyzing your cut-off requirements, Kinkelder can reduce the number of different saw blades used. At the same time we can often improve blade life and reduce cut time by fine tuning cutting parameters.

The reduction in variation of saw blades will make stock management easier and will reduce the amount of money tied up in blade inventory. Supply us your list of cut-off applications along with available machinery and required output/line speed and we will make a preliminary assessment of what we can do for your operation.

Tooth breakage

When small particles break away from the cutting edge (mostly occurring on carbide tipped saw blades), this is usually caused by:

 

  • Chips sticking to the tooth face. Excess pressure on the cutting edge will cause chipping. Use or add a wire brush, cold air gun or better cutting fluid.
  • Increase tooth pitch. More room between the teeth will reduce chances of chips getting stuck between the teeth
  • Unstable, thin walled product. Vibration of the product during the cutting operation can cause tooth breakage. Improve the clamping system or change cutting parameters to reduce this vibration. Alternatively, change to another tooth geometry
Improve cut quality

Reduce burr


  • Inside (ID) burr
    1. Dull saw blade
    2. Wrong geometry or poor regrind
    3. Wrong Tooth pitch
    4. Saw blade vibration problem - machine condition, saw blade insecure

 

  • Outside (OD) burr
    1. Feed rate too low (pigtail), before increasing it, check the fill ratio
    2. Dull saw blade
    3. Wrong geometry or poor regrind
    4. Cutting speed too high

 

  • Improve surface quality
    1. Scratched surface - Some tooth damaged - replace saw blade
    2. Rough surface (HM)
        2a. Vibration - wrong parameters (change cutting speed and / or feed rate)
              - Wrong blade choice - change blade type or geometry
        2b. Wave - increase feed rate
        2c.  Rough wave - increase cutting speed
Increase line speed

When the cut off time is limiting the speed of your tube line, Kinkelder has several types of saw blades and services available.

  • SpeedMaster carbide tipped saw blades for extremely high cutting speeds and feed rates (for single blade and Twin blade machinery)               
  • Tubemaster carbide tipped saw blades for orbital cutting
  • Scarfmaster carbide tipped saw blades for sawing ID-scarfed tubes up to 219x10
  • HSS-saw blades with a coating dedicated for high speed cutting
  • HSS-saw blades with an optimized tooth geometry to allow very high feed rates
  • HSS-saw blades with fully coated teeth + recoating services for  a 40% reduction of cut time

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