Troubleshooting

What to do, if:

Problem Probable cause Solution

Broken band saw blade (straight brake indicates material fatigue)

  • Inappropriately choosed band saw blade
  • Blade tension is too high
  • Cutting rate too high
  • Wrong lubrication
  • Small diameter of impellent wheel
  • Blade guidance worn down
  • Blade rubs the flange of impellent wheel
  • Teeth in contact with workpiece before cutting initiation
  • Side guidance too tight
  • Tooth pitch too coarse (small TPI) - see Choice of TPI
  • Reduce blade tension - see table with recommendet tension
  • Reduce cutting speed
  • Check cutting emulsion
  • Use smaller blade - sie machine manual
  • Check pressure in guidance clamps. Exchange of worn down ones.
  • Set wheel position
  • Set 10mm gap between saw and workpiece
  • Adjust guidance clamps

Premature teeth wear down

  • Band saw blade is put on in wrong way
  • Incorrect running-in
  • Hard parts in material
  • Material hardness is too high
  • Wrong lubrication
  • Cutting speed to high
  • Cutting rate too low
  • Put on the blade in right direction
  • Reduce cutting rate and speed when running-in according to manufacturer"s recommendations
  • Check the real material hardness
  • Increase cutting speed and cutting rate
  • Lubrication check-up
  • Reduce cutting speed - see recommended cutting speeds
  • Increase cutting rate - see recommended cutting rates

Inexact cut

  • Teeth are worn down
  • Cutting rate too high/low
  • Wrong TPI
  • Irregular input of lubrication
  • Guidance clamps worn down or loose
  • Use new band saw blade
  • See recommended cutting rates
  • See choice of TPI
  • Adjustment of lubrication nozzle
  • Faster or exchange defective

Undercutting - movement of the blade in cut

  • Cutting rate too high
  • Insufficient band tension
  • Teeth setting worn down
  • Teeth worn down
  • Tooth pitch to fine (great TPI)
  • guidance clamps worn down or loose
  • See recommended cutting rates
  • See recommended band tension
  • Check material hardness
  • Use new band saw blade
  • Use coarse tooth pitch (smaller TPI)
  • Faster or exchange defective

Squeezed chip

  • Incorrect lubrication/small quantity
  • Cutting speed/rate too high
  • Tooth pitch to small (great TPI)
  • Lubrication check-up
  • Cutting speed or rate reduction
  • See choice of TPI

Teeth are falling off

  • Cutting rate too high
  • Squeezed tooth in cut
  • Cutting liquid - incorrect/small quantity
  • Hard part in material
  • Inappropriate tooth pitch (TPI)
  • Insufficient workpiece clamp
  • Teeth in wrong direction
  • Reduce cutting rate or speed
  • See recommended cutting conditions
  • Use new band saw blade
  • Check emulsion
  • Material hardness and qualiti check
  • See choice of TPI
  • Clamp check-up; Make sure that workpiece is fastened firmly
  • Put on the blade the right way

Wear down on the back of the blade

  • Insufficient tension
  • Wrong band saw blade
  • Cutting rate too high
  • Upper guidance clamp defect
  • Guidance clamps too wide from eachother or loose
  • Blade in contact with flange of impellent wheel
  • See recommended band tensions
  • Choose variable tooth pitch
  • Reduce cutting rate
  • See recommended values
  • Increase pressure; if they are worn down - exchange, never sharpen)
  • Move guidance clamp towards workpiece
  • Toe settings

Brake on the tooth back (indicates spinning of workpiece)

 

  • Wrong cutting rate/speed
  • Wrong tooth pitch
  • Guidance clamps squeezed, worn down, too far from each other or defective
  • Band saw blade in contact with workpiece
  • See recommended cutting conditions
  • See tooth pitch, adjust or exchange clamps
  • Set tension pressure
  • Set 10mm gap between saw and workpiece

Irregular brake (indicates movement of workpiece)

  • Material is not fastened right in the clamp
  • Check hydraulic pressure

Cracks between teeth

  • Roller or guidance clamp worn down
  • Guidance clamps too far from each other, worn down or loose
  • Side guidance clamp in contack with teeth
  • Incorrect tension
  • Check wheels and guidance clamps
  • Increase pressure; if they are worn down - exchange, never sharpen)
  • Set guidance clamps into correct position
  • Check real tension by tensometer

Raw surface, vibration or trembling

  • Band saw blade worn down or defective
  • Incorrect feed rate or cutting speed
  • Insufficient blade guidance
  • Insufficient blade tension
  • Incorrect tooth pitch
  • Use new band saw blade
  • See setting of cutting conditions, adjust until the problem disappears
  • Set guidance clamps, sufficiently close
  • See recommended tension
  • See choice of TPI

Scratches on side, set wear down

  • Guidance clamps are rubbing the blade
  • Insufficient tension
  • Wrong blade width
  • Hard parts in material
  • Set guidance clamps
  • See recommended band tensions
  • See machine manual - recommended band saw blade
  • Check material hardness

Tooth tips became bluish

  • Wrong tooth pitch
  • Incorrect feed rate or cutting speed
  • Wrong (or not enough) lubrication
  • Insufficient chips removal
  • See choice of TPI
  • See setting cutting conditions
  • Check cutting lubrication
  • Check cleaning brush

Brake in the weld

  • Wrong welded (insufficiently tempering)
  • Band saw blade tension too high
  • Check welding process
  • Reduce blade tension

Skipping of the blade 

  • Crooked weld
  • TPI too fine (more than 30 teeth in cut)
  • Teeth are breaking off
  • Cutting rate too low
  • Check welding process
  • See choice of TPI
  • Use new band saw blade
  • See setting cutting conditions

 

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