Bandsaw Machinery and the use of (Blades). Solving Problems with Cutting

Bandsaw cutting has made significant steps and progress over the years, customers also require to be aware of what is happening to the blades in the cutting process

Cutting Process

Bandsaw requires attention to the process at hand. Keeping a close eye on the band, when cutting and looking at discarded blades, can give a good indication of great cutting or  something is not quite right.

Help Solving problems Bandsaw Blades

Problem Probable Cause Solution
Blade Breakage
  • Incorrect blade
  • Band tension too high
  • Excessive feed
  • Incorrect cutting fluid
  • Wheel diameter too small for blade being used
  • Worn or chipped pressure block (back-up guide)
  • Blade rubbing on wheel flanges
  • Teeth in contact with work before starting saw
  • Side guides too tight
  • Teeth too coarse. Check your cutting chart *
  • Reduce band tension. See Machine Operator’s Manual
  • Reduce feed pressure
  • Check your coolant *
  • Use thinner blade and lower speed
  • Check pressure block. Replace if worn
  • Adjust wheel alignment
  • Allow 1/2″ clearance before starting cut
  • See Machine Operator’s Manual
Premature Dulling of Teeth
  • Blade teeth inverted (backwards)
  • Improper break-in period
  • Hard spots in material (like scale)
  • Material work hardened (check for hardness and adjust feed)
  • Improper cutting fluid or mixture
  • Speed and feed too high
  • Install blade correctly
  • Reduce feeds and speeds during break-in period in accordance with manufacturers’ recommendations
  • Check material for actual hardness – hard spots like scale or flame cut surfaces
  • Increase feed pressure
  • Check your coolant *
  • Check your cutting chart *
Inaccurate Cut
  • Teeth dull
  • Over or under feed
  • Improper pitch blade
  • Cutting fluid not applied evenly
  • Incorrect blade (too many teeth per inch)
  • Guides worn or loose
  • Use new blade
  • Check your cutting chart *
  • Check your cutting chart *
  • Adjust coolant nozzles
  • Check your cutting chart *
  • Tighten or replace guides
Band Leading in Cut
  • Over feed
  • Lack of band tension
  • Tooth set damage
  • Loose guide arms or set too far from work
  • Check your cutting chart *
  • Check Operator’s Manual for correct tension
  • Check material hardness
  • Adjust arm as close to work as possible – tighten and align. Check guide
Chip Welding
  • Improper or lack of cutting fluid
  • Wrong coolant
  • Excessive speed or pressure
  • Incorrect blade (wrong pitch)
  • Check your coolant *
  • Check your coolant *
  • Reduce speed or pressure. Check your cutting chart *
  • Check your coolant *
Teeth Fracture Back of tooth
  • Incorrect feed and/or speed
  • Incorrect blade (wrong pitch)
  • Saw guides not adjusted properly
  • Check your cutting chart *
  • Check your cutting chart *
  • Adjust or replace saw guides
Irregular Break
  • Indexing out of sequence
  • Material loose in vise
  • Check for correct indexing sequence (head rise)
  • Check hydraulic pressure
Teeth Stripping
  • Feed pressure too high
  • Tooth lodged in cut
  • No cutting fluid or incorrect coolant
  • Hard spots, scale, inclusions, etc.
  • Incorrect blade (wrong pitch)
  • Work spinning in vise; loose “nest” or bundles
  • Blade teeth running backwards
  • Reduce feed pressure and/or speed. See your cutting chart *
  • Never enter same (old blade), cut with new blade
  • Check your coolant *
  • Check hardness. Descale and/or anneal if necessary
  • Check your cutting chart *
  • Check hydraulic pressure; be sure work is firmly held
  • Reverse blade teeth, turn inside out
Wear on Back of Blades
  • Insufficient blade tension
  • Incorrect blade (back too soft)
  • Incorrect feed (excessive)
  • Back-up guide frozen in position, damaged, or worn off
  • Guide arms too far apart, cocked, worn or loose
  • Blade rubbing on wheel flanges
  • See Machine Operator’s Manual for correct band tension
  • If using hard back blade, switch to a variable tooth
  • Reduce feed pressure. See your cutting chart *
  • Free pressure block and realign; if worn, replace (never regrind)
  • Move arms close to work as possible
  • Adjust wheel alignment
Rough Cut
  • Dull or damaged blade
  • Incorrect feed and/or speed
  • Lack of band support
  • Insufficient band tension
  • Incorrect pitch blade
  • Replace with proper blade
  • Check your cutting chart *. Adjust until noise disappears
  • Set guide arm properly – close to work as possible
  • Check Operator’s Manual for correct tensions
  • Check your cutting chart *
Wear Lines, Loss of Set
  • Saw guide inserts or roller are riding on teeth
  • Insufficient blade tension
  • Incorrect blade (width of blade incorrect)
  • Hard spots
  • Back-up guide worn
  • Check table and Operator’s manual for correct blade width
  • Check for correct blade tension
  • Check your cutting chart *
  • Check material hardness
  • Replace back-up guide
Twisted Blade
  • Band binding in cut
  • Side guides adjusted too tight
  • Work not held firmly
  • Incorrect (or lack of) cutting fluid
  • Check table and Operator’s manual for correct blade width
  • Check for correct blade tension
  • Check your cutting chart *
  • Check your coolant *
Blade Wear
  • Incorrect blade
  • Incorrect feed or speed
  • Improper (or lack of) cutting fluid
  • Check your cutting chart *
  • Check your cutting chart *
  • Check your coolant *
Teeth Fracture Front of tooth
  • Material loose in vise
  • Incorrect blade (wrong pitch)
  • Check hydraulic pressure
  • Check your cutting chart *