Forces, wear modes, and mechanisms in bandsawing steel workpieces

Abstract

Bandsawing is an important primary operation in a variety of industries, particularly steel suppliers who need to cut-off raw material for secondary processes. Bandsawing is a competitive method of cutting to size as it achieves a low kerf width, high metal removal rates, and good surface finish. One specific feature of the bandsaw metal-cutting operation is that the depth of cut per cutting edge is small (5–50 μm). Under conditions of low depth of cut and restricted chip formation, metal is removed by a complex combination of fragmented chips, ploughing, and some continuous conventional chips. The process of bandsawing is scientifically evaluated by measuring forces and associated parameters. Wear modes and mechanisms are also monitored, characterized, and their validity discussed.