Band saw machine for metal. Band saws for metal (band saws)

Band sawing technology has long acquired the status of a reliable and popular method of processing metal blanks. Its main representative is the automatic band saw machine.

Automatic band saws for metal - a powerful and productive alternative to hand saws in conditions large enterprise. They are used for cutting metal profile various sections and sizes. As a rule, such machines interact with steel, non-ferrous metals and high-strength workpieces and, partly for this reason, they are so in demand at industry plants. With the help of a band saw machine, a part is obtained with a high quality of processing that does not require further adjustment. This significantly saves time and resources of the enterprise.

There are several types of band saw automation, each of which finds its user depending on the technological task and available budget.

Level 1 automatic band saw, these are machines equipped with automatic feeding of the workpiece with the help of driven vise rollers to a pre-set limit sensor for the required length. The speed of rotation of the band saw blade, the lowering of the saw frame and the clamping-unclamping of the workpiece is carried out using a push-button control panel. The length of the cut workpiece in this case is constant.
Automatic band saw machine with a PLC programmable logic controller, the length of the workpiece to be cut in this case is already set from the control panel and controlled by the encoder. These machines have a memory of up to 8 programs that can be set in the order you need. The feed of the workpiece here is also carried out using the drive rollers of the vise.
There is also the following type of automation, this is an NC controller, or in other words - a “smart controller” with a memory of up to 99 programs, with a touch control display and a library of cutting modes. Such machines are already equipped with double discs, one of which is feeding, the second is clamping and fixing workpieces. This method of feeding has the highest accuracy and repeatability of cut products.

An important point is the type of machine design: cantilever, column or on linear guides. Console-type machines are used for cutting workpieces up to 450 mm and have a less rigid structure than a column-type one, which, in turn, due to the two support points of the saw frame, has more high level susceptibility to loads, especially when sawing solid material with a large section, and the durability of the machine. The portal type on linear guides has the same advantages, but high straightness and cutting accuracy are also added here.

Any type of band saw can be equipped with a hydraulic device for batch cutting of workpieces, which will significantly increase productivity when sawing small sections of metal.

The working bodies of the machine are made of reliable metal and cast iron alloys, which provide the band saw with structural strength and additional stability during operation ( hard metals absorb unwanted vibrations).

The KAMI company sells automatic band saw machines for metal. The company's assortment includes a large selection of models, among which are units of both console and portal types. When choosing equipment, you should definitely look at power - a key characteristic of an automatic machine.

The implementation of new developments and the pace of development of science and technology require the use of high-tech equipment in the production. Band saw machine for metal fully meets the requirements of the time.

1 Band saw for metal - what is it?

This is a powerful equipment for both straight and figured cutting not only of metal, but also of wood, plastic, and other materials. The working body of the machine is a band saw - a closed (endless) metal strip with teeth. It moves continuously in one direction in a closed loop on 2 or 3 pulleys. The peculiarity of the design and movement of the saw blade provide a long working life of the long cutting surface of the tape. Therefore, the saw slowly dulls and does not need to be replaced frequently.

The power of the electric motor that drives the pulleys determines the performance and efficiency of the machine, and is the main criterion when selecting a band saw blade. Since the forward movement, and therefore the pressure of the saw, is always directed towards the material to be processed (toward the working table), there is no danger of the workpiece being thrown into the operator.

The band saw machine for metal is compact and occupies a small area. The series for home workshops, small scale production is quite light and does not require lifting equipment for installation. A high-quality tape blade makes little noise during operation. There are a lot of types and modifications of machines with a band saw, but they all consist of the main structural units:

frame;
drive mechanisms;
saw knot;
systems for loading and supplying workpieces;
electromechanical and hydraulic control devices for equipment mechanisms.

2 The principle of operation of the tape machine and its capabilities

As a rule, a belt stretched over 2 flywheels is used in the drive mechanism of the machine. When the equipment is turned on, the belt is set in motion, and the master can load the workpiece for cutting. The cuts made by the machine are very accurate, which is achieved due to the uniform distribution of pressure during metal processing. Cutting on a machine with a band saw is standard (perpendicular to the axis of the equipment) or at an angle (any, not exceeding 60 °).

The second mode is carried out by changing the location of the working body (sawing blade) or by tilting the rotary frame. Cutting at an angle greatly simplifies the processing of workpieces. Coolant (cooling fluid) is used to protect the saws from overheating during operation. It can be water or a liquid viscous composition, continuously supplied to the blade of the blade and washing it. The coolant not only protects the saw from destruction and rapid wear, but also helps to reduce dust from metal particles.

Another important function is the possibility of equipping the machine with special brushes that continuously clean chips and dust from the blade of the blade. This allows you to get a better and even cut. In addition, the use of brushes also increases the life of the saw and protects the operator from cutting debris.

Used band saws for metal are divided into:

carbon - for cutting non-alloyed and alloyed steels;
bimetallic - for heavy cutting conditions;
carbide - for cutting hard-to-cut metals (alloys with a high content of titanium and nickel, cast iron);
diamond - for cutting abrasive materials.

3 Classification of tape machines by design

By design, they are divided into groups:

4 Classification of tape machines by degree of automation

According to the degree of automation, machines are divided into:

manual (gravity);
semi-automatic;
automatic.

Usually manual machines are structurally performed as console ones. In them, the saw frame is lowered by the efforts of the worker, overcoming the opposition of the spring. In manual gravity - due to the own weight of the frame. In this case, the feed rate of the frame is regulated by a hydraulic cylinder with a bypass valve. Such a system is called hydraulic unloading, it also serves to lift and fix the frame at the original top point.

The operator of the equipment sets, measures and secures the workpiece in a vise with a manual clamp. The frame lowers at a speed set manually or from a portable control panel.

Advantages of manual band machines for metal:

low cost, inexpensive operation and maintenance;
most often, cutting at an angle is possible.

Flaws:

frame lowering methods often cause the saw to vibrate when cutting and contribute to a sharp decrease in blade life;
frequent lack of visual control of the degree of saw tension and blade cleaning mechanisms;
mandatory periodic adjustment of the cutting blade drive pulleys;
lack of adjustment and control of the pressure of the saw on the part (the valve on the cylinder regulates only the feed rate in a narrow range).

Manual machines are used for small industries for cutting stainless and tool steels, light and non-ferrous metals, both solid blanks and profiles. In semi-automatic band machines, the saw frame is lowered and raised, the vise is clamped and opened automatically by a hydraulic drive. Only the supply of blanks is done manually by the operator.

After starting, the machine fixes the workpiece in a vice, cuts at a given speed. The pressure on the part is carried out not only by the weight of the frame, but also by the force that the hydraulic cylinder creates. This allows you to cut more complex materials(for example, solid blanks made of stainless steel). When the saw frame reaches the lower position, the microsensor is activated. After that, the frame is raised to the upper position and the vice is released.

Semi-automatic machines are suitable for small batch production and are the most popular model group. They cut at various angles from -60° to +60°. Design - single-column, two-column, cantilever.

Automatic use on large industries for cutting a huge number of serial blanks. The main advantage is that the operator only places the workpiece in a vise and sets the required parameters. After launch, all actions are performed automatically. The cutting force is adjustable at each stage. To prevent the saw from breaking, when the pressure on the blade increases, the smooth feed of the frame slows down or stops. There is a manual mode with control of basic operations.

Automatic machines are more productive, more precise and automatically produce complex bevel cuts. They can operate in a three-shift mode and cut long workpieces into specified fragments without an operator. It is possible to cut workpieces of the same or different lengths in 1 cycle. Design - single-column, two-column, cantilever, vertical, portal.

5 Advantages of cutting on a metal band machine

Machining is the main technological method in the manufacture of parts and mechanisms, machines. The main difficulty in cutting is too large allowances that have to be left for subsequent processing. This is a consequence of the insufficiently high accuracy of preparatory operations and complicates and increases the cost of machining processes.

The most well-known metal cutting methods with chip removal:

cutters (circular saws) on circular saws;
cutters or cutters on special cutting equipment;
hacksaw blades on hacksaw mechanical machines;
band saws on band machines.

The latter method, in comparison with the others, is characterized by the following advantages:

higher performance;
high accuracy - 0.1–1.5 mm, maximum deviation from the vertical 0.05 mm;
higher cut quality;
saving metal consumption due to the small width of the cut (up to 1.5 mm);
possibility of work at an angle up to ±60°;
provides cutting of all types of workpieces - pipes, long products, solid blanks, forgings, castings;
the ability to process batches of blanks.

The band saw machine is designed for cutting profile and sheet blanks from various kinds steel, non-ferrous metals, cast iron on products of a given size at a given angle. Batch cutting of blanks is possible in case of a small section. The cutting part is represented by a closed saw blade band with teeth made of hard alloy. Band saws for metal in our catalog are represented by the brands MetalMaster (Asia). Band saws are designed for high-performance cutting of all types of metal used in modern engineering, including high-alloy and heat-resistant steels, hard-to-cut alloys. The use of a band saw machine allows you to optimize metal consumption by reducing the width of the cut, increase productivity and reduce the cost of consumed electricity. Band saws Metal Master (China) and Pilous (Czech Republic) are widely used in mass and serial production. TAPKO-M specialists help you make the right choice of a machine that most closely matches the tasks of your production.

Video: metal band saw MetalMaster PT

The production of band saws manufactured under our MetalMaster brand is located in Asia. TAPKO-M engineers are always present at the acceptance of finished products, so we guarantee our customers high quality all machines. We also have the opportunity to optimize production costs and the cost of band saws for metal. The price of a band saw from TAPKO-M is always optimal for any client, because we are ready to negotiate your personal discounts and provide convenient payment terms. It is very simple to buy a band saw machine: study the information in this section of the site, call to clarify your price and find out other interesting details of the sale of band saw machines.

How to choose a band saw for metal?

If you want to buy band saw inexpensive but reliable technical specifications, you should get rid of stereotypes. Because we actively encourage all customers Russian market machine tools for metal to buy and use Chinese band saw machines. China is the motherland ancient civilization, the mother country of many technologies - porcelain, tea, thermoses, cotton products. The Chinese are real hard workers. This is the highest rate of their development in the last decade. Cooperating with large manufacturing companies in China, we confirm the reliability of all our partners and vouch for the quality of equipment. Metal cutting with a band saw made in China under our MetalMaster brand will be guaranteed to be of high quality and flawless. Well, if your current budget does not allow you to purchase a new machine yet, you can always look for machines in the secondary market. Seeing the ad: "I will sell the band saw machine", - specify it trademark. If it's MetalMaster - you can take it!

Cutting on a band saw can be manual, semi-automatic and automatic. Such broad opportunities are represented by our supplier of vertical band saws and MetalMaster horizontal band saws, which are no less in demand in the production.

The increase in importers of vertical metal band saws in our country has led to a problem right choice band saw cutting machine on the Russian market.

The selection of band saw equipment must begin with a clear definition production task. You should understand the type of product that you want to get as a result. Consequently, technical specifications machine are determined based on the task, due to the size of the workpieces being processed, the brand of material and its physical properties, the required capacity and equipment load factor.

Band saws for metal are equipment designed to cut materials according to a given program. This type equipment is widely used in various industries and construction of construction sites.

Production of band saws

The main manufacturers of high-quality equipment intended for a wide range of enterprises are the world leaders in the field of machine tool building:

Delta (Korea);
Amada (Japan);
Daito (Japan);
Kasto (Germany);
Behringer (Germany);
Everising (Taiwan);
Carif (Italy);
Doall (USA);
FMB(Italy);
Danova (Spain);
Jet (Switzerland);
Proma (Czech Republic);
Optimum (Germany);
Bomar (Czech Republic).

Manual band saws are mainly used for processing plastics, metals - cast iron, low-alloy and non-alloy steel, non-ferrous metals, titanium and nickel alloys.

Coolant supply to the cutting zone

Metal processing can be carried out at a right angle or a given angle, not exceeding 60º. Changing the cutting angle is done by changing the position of the cutting saw when the frame is rotated. The cutting process is controlled by sensors, and the working area of contact between the metal being processed and the saw is cooled by the supplied coolant. Water or a special emulsion can be used as a coolant, which also washes away chips and metal dust. On some models of machines, cleaning brushes are installed that remove metal chips, thereby contributing to better sawing of metal and increasing blade life.

Benefits of using

This group of equipment has certain advantages:

the ability to cut metal up to 400 mm thick;
material can be cut in a wide range of angles;
during the working process, the material is cut with the formation of a smooth edge;
a band saw for metal refers to equipment that occupies a minimum of production space;
low noise level during production of technological operations.

Band saws are high-performance equipment and are used when carrying out technological operations that cannot be performed on other devices.

Technological progress does not stand still, forcing manufacturers of metalworking equipment to translate the latest achievements of science and technology into modern high-tech equipment. Band saws for metal were no exception and fully meet the requirements of the time.

PJSC Kuvandyk Plant KPO Dolina is one of the few domestic manufacturers of band saws that has mastered and offers customers a full range of additional features for the entire line of manufactured machines.

Our factory produces band sawswith varying degrees of automation, allowing to make cutting practically of any hire. The entire line of machines is designed in such a way as to ensure the most even distribution of pressure on the workpiece during the cutting process, which allows you to get very accurate cuts. Depending on the selected configuration, metal cutting can be performed both perpendicular to the equipment axis and at an angle not exceeding 60 degrees. Unusually, miter cutting is achieved either by rotating the movable part of the vise or by rotating the worktable.

To equip serial production, where there is a need to cut a large number of the same type of workpieces, we use automatic band saws for metal. If it is necessary to make several single cuts, such band saws are switched to manual control mode.

Automatic machines according to a given program can work without the presence of an operator, performing the same type of operations (cutting long workpieces into parts of a given length) a given number of times, which allows one operator to service several machines at once.

It is also relevant in conditions of large series to apply batch cutting of workpieces from a profile with a small cross-sectional area. Our company offers consumers two options for solving this problem at once:

The first way is to use additional devices to obtain the so-called "hexagonal vise". Hexagonal vise allows you to most compactly stack round or, for example, hexagonal workpieces in a bag, which is very difficult to do when using a conventional vice.

The second method involves the use of an additional upper clamp. When using the top clamp, it is possible to lay workpieces of almost any profile in a relatively compact package. When using a conventional vice, it is problematic to achieve reliable fixation of a package of workpieces of small cross section (for example, welding of the ends of the workpieces or tying the package with wire is used).

High metal cutting performance (even when using additional options such as batch cutting) cannot be achieved without the use of automatic feeding blanks. Automatic feeding can be carried out different ways: the use of feed roller tables in conjunction with control electronics; embedding feed rollers in a vise or machine table; etc., but all of these methods are not applicable in a batch cutting environment. When cutting metal with a package, this very “package” must be constantly clamped in a vice. The solution to this problem was the use of an additional feed vice on our automatic band saws..

The use of this principle of automatic feeding when using batch cutting allows you to significantly increase the productivity of the equipment, and also significantly reduce the time spent by the operator.

Important when using band saws is the ability to cut metal at various angles. Most manufacturers offer fixed cutting angles such as 15, 30 or 45 degrees. On the machines of PJSC Kuvandyk Plant KPO Dolina it is possible to cut metal l la at any angle in the range 0±45 or 0±60 degrees.

Implement this opportunity engineers of our company succeeded by changing the concept of cutting at an angle. While most of the world's manufacturers use the principle of rotation of the workpiece relative to the band saw machine, our designers have implemented the principle of rotation of the machine relative to the axis of the workpiece.The advantage of this solution is fully visible when calculating the required area for equipment.

The use of all of the above functions when working on band saws manufactured by PJSC Kuvandyk Plant KPO Dolina provides undeniable advantages:

It should be remembered that no matter how much automation the machine has must be strictly observedregulations Maintenance and monitor the accuracy of the resulting cut for which you need: