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hefabricator.com/article/tubepipeproduction/choices-in-flying-cutoff-saw-blades&title=Choices+in+flying+cutoff+saw+blades&
+machines+for+tube+and+pipe+mills.+Drawbacks+include+hazards+%28noise+and+risk+of+breakage%29+and+burrs+they+tend+to+generate.+Tungsten-
re+more+sophisticated+sawing+machines%2C+run+slower+and+safer%2C+cut+cleaner%2C+and+are+less+prone+to+breakage.&img=http:
w-blades-flying-cutoff-saw-blades.jpg)
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Friction saws are the conventional cutoff machines for tube and pipe mills. Drawbacks include
hazards (noise and risk of breakage) and burrs they tend to generate. Tungsten-carbide-tipped
(TCT) blades, which require more sophisticated sawing machines, run slower and safer, cut cleaner,
and are less prone to breakage.
(http://image.thefabricator.com/a/choices-in-flying-cutoffsaw-blades-flying-cutoff-saw-blades.jpg)
That said, friction saws do have disadvantages. Safety
is one concern. Friction blades are large in diameter, and
depending on the rotational speed, the linear velocity at the tips of the teeth can exceed 180 feet per second (FPS).
Breakage at such a speed can cause severe damage to the machine and its surroundings. Also, they tend to generate
quite a bit of noise and heat (see Figure 1). In many cases, extra precautions, such as sound attenuation cabinets and
protective shields, must be in place to conform to OSHA regulations. The service life of friction blades can be inconsistent,
and therefore can cause unexpected line stops and tool changes.
Advances in blade geometry and coating technology have made tungsten carbide-tipped (TCT) circular saws a viable
option. TCT blades typically are smaller in diameter and run at lower peripheral speeds than friction blades. Blade
breakage is less an issue, and if a crash does occur, flying debris is a smaller hazard. Also, TCT blades run quietly. Sound
attenuation cabinets are not necessary.
Because TCT saws draw a chip at the workpiece, material removal is clean, precise, and repeatable throughout the cut
(see Figure 2).
The most important advantage of TCT circular saws in tube production is durability. Depending on the tube size and
workpiece material grade, a TCT blade can last up to four shifts.
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RELATED CONTENT
23/02/2016 17:33
http://www.thefabricator.com/article/tubepipeproduction/choices-in-flyin...
Switching to TCT blades isn't as simple as installing new blades on an existing saw. TCT blades require a more
sophisticated equipment setup than
friction blades do. Five tips can help you get started in planning the switch.
1. A TCT blade runs at a lower peripheral speed and higher chip loads, so you should plan to reduce the cutting
speed. A good target is 12.5 to 25 FPS.
2. To get the best results, you need precise feed control. An optimal cut relies on a variable-speed system that
allows you to use a slow feed rate as the blade enters the tube, a fast feed rate for making the cut, and a slow
feed rate as the blade exits the tube. The feed system should provide accurate and backlash-free movement.
3. The reduction gear between the drive motor and saw blade should be free of play and preferably have
pretensioned gear engagement.
4. The operator interface should indicate the motor's current consumption (measured in amps).
5. You should be able to fine-tune the motion so that the carriage speed matches the line speed.
a-common-sense-approachfor-vacuum-tube-and-solid-statemachines)
(http://image.thefabricator.com
/a/choices-in-flying-cutoff-saw-blades-friction-sawing-resultsburrs.jpg)
Figure 1 Friction sawing usually generates heat that softens the
workpiece, resulting in a burr which must be removed before
shipping the product.
2 of 5
(http://image.thefabricator.com/a/choices-in-flying-cutoff-saw-blades-tct-blade-
clean-cut.jpg)
Figure 2 Tubes cut by a TCT blade exhibit a clean cut. In most cases, the workpieces do not require deburring.
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23/02/2016 17:33