Longer. Straighter. Faster.  These three simple words sum up the needs of production saw users. Manufacturers are very aware of this and are always working to improve the technology needed to achieve longer lasting, straighter and faster blades. The band saw industry has been around for a very long time and despite its reputation as a mature industry, it is always advancing technologically to meet the ever-evolving needs of its users. Now more than ever, metal operations that rely heavily on band sawing to turn a profit need to take every measure possible to ensure their operations are running efficiently in order to bid low and win jobs. To answer this need, world-class band saw blade producers are going back to the drawing board to develop that next generation of band saw technologies that will give their customers an edge in the marketplace.

Technology.The same technologies previously developed in other cutting tool industries are now being optimized in the development of new and improved products.  In order to effectively advance band saw technologies, manufacturers must find ways to reduce cost per cut. Focus must be put into new cutting edge and backing materials for bi-metal blades, improved carbide tipped products, coatings (TiN and AlTiN), heat treating techniques, and new tooth forms designed by using advanced computer modeling techniques. Top manufacturers are working to blend these technologies together into their own “special sauce” which will yield important new products for its customers.

Blade Surface Preparation Techniques

Manufacturers are now focusing on advancements in specialized blade surface preparation techniques. One of the key benefits of this technology is that it dramatically reduces the occurrence of band breakage due to metal fatigue. Premature band failure due to metal fatigue can be the result of many factors or combination of factors including improper band tension, band guides in poor condition or improperly adjusted, improper tracking of the band on the wheels, and conditions where bands are required to twist severely between the wheel and guides. In all these cases, however, the stresses on a blade usually begin on points that are metallurgically susceptible to cracking.

Blade Surface Preparation Process

Blade surface preparation, which takes place after heat treatment and tempering, significantly reduces the occurrence of cracking under stress. The blade preparation process places a very thin external layer of the blade material under compression. When the surface is compressed, it is less likely to crack. Surface preparation also ensures that each tooth tip is rounded into a stable, maintainable surface that can endure the rigors of cutting forces and vibrations, resulting in a more consistent and longer lasting cutting tool.

Peening is one blade surface preparation technique increasingly used to combat stress fractures. It is a relatively new process to the band saw industry, but has been used successfully in the aerospace industry where fatigue life is a constant concern. Unlike applications in other industries, the relatively thin cross-section of a band saw blade creates a major challenge for manufacturers in determining the optimum stress configuration for the band material.

Peening or shot peening is defined as stressing the surface layer of a material by bombarding it with a selected medium (usually round steel shot) under controlled conditions. In addition to steel shot, there are several other media available such as glass and ceramic bead and cut wire. Each is selected based on the material being peened and desired outcome. Once this is determined, the ability to achieve this needs to be developed through the application of several parameters that include the material and size of shot media and the intensity and duration of the process itself. An additional challenge is developing and implementing the technology while maintaining competitive cost structures. Peening is a complex machining process, but the finished product is simple; a blade with improved resistance to breakage due to fatigue and a much more consistent edge.

Going forward, the best products introduced to the band sawing industry will optimize all available technologies and provide the users with more advanced blades that cut longer, straighter and faster than existing products on the market. Another key component is the use of advanced surface preparation technology. The world’s top blade manufacturers are preparing now for the next revolution in blades, knowing that machines will continue to get better, materials will continue to get stronger and productivity will become even more important to users worldwide.

Gerry Overstreet is a product manager for LENOX ®, 301 Chestnut St., East Longmeadow, MA 01028, 413-525-3961, www.lenoxtools.com.

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