A bandsaw is a versatile tool that allows for precise and efficient cutting in various materials. However, encountering issues with the bandsaw blade can hinder the cutting process and result in subpar results. In this guide, we will address common bandsaw blade problems and provide effective solutions to troubleshoot them.
Problem 1
Premature Band Saw Blade Breakage
Cause of the Problem
- Incorrect band saw blade teeth (TPI) used
- Incorrect blade speed
- Blade tension set too high
- Side guides tightened excessively
- Damaged or misadjusted band saw blade guides
- Excessive feed pressure
- Incorrect cutting fluid
- Blade rubbing against wheel flanges
Solution
- Use a band saw blade with a correct tooth pitch (Refer TPI selection)
- Increase or decrease the blade speed as recommended.
- Reduce the tension of the band saw blade
- Check side guide clearance and adjust if necessary
- Inspect and realign or replace damaged guides
- Reduce the feed pressure
- Check and ensure the proper application of cutting fluid
- Adjust wheel alignment to prevent rubbing
Problem 2
Premature Band Saw Blade Dulling of Teeth
Cause of the Problem
- Improper or no blade break-in
- Excessive blade speed
- Light feed pressure
- Presence of hard spots in the material
- Incorrect band saw blade teeth (TPI) used
- Incorrect coolant concentration
- Band saw blade mounted incorrectly, with teeth pointing in the wrong direction
Solution
- Break in the blade properly, following recommended break-in procedures for the specific material
- Adjust the blade speed to the recommended setting
- Increase the feed pressure if necessary
- Check the material for hardness, scale, or flame-cut areas
- Use a band saw blade with a correct tooth pitch (Refer TPI selection)
- Verify the coolant type and concentration to ensure optimal performance
- Install the band saw blade correctly, ensuring the teeth face the right direction
Problem 3
Cutting not straight
Cause of the Problem
- Insufficient blade tension
- Worn or loose guides
- Excessive feed pressure
- Saw guide arm too far apart
- Tooth set damage
- Uneven application of cutting fluid
- Improper tooth size
Solution
- Adjust the blade tension to the recommended level.
- Tighten or replace guides, ensuring proper alignment
- Reduce the feed pressure to achieve more accurate cuts
- Adjust guide arm closer to material
- Replace new blade
- Verify that cutting fluid is evenly applied using appropriate nozzles
- Refer to the Tooth Size chart to ensure the proper tooth size for the specific material
Problem 4
Teeth Stripping
Cause of the Problem
- Improper break-in
- Excessive feed pressure
- Blade tooth getting stuck in the cut
- Workpiece spinning or moving in the vise or clamp
- Hard spots in the material
- Incorrect tooth size
- Band saw blade speed set too slow
- Blade teeth running backward
- Malfunctioning chip brush
- Improper or insufficient coolant application
Solution
- Break in the blade properly, following recommended break-in procedures for specific material
- Reduce the feed pressure to prevent teeth stripping
- Avoid entering an old cut with a new blade to prevent tooth sticking
- Ensure the workpiece is securely clamped to prevent spinning or movement
- Inspect the material for hard inclusions that may cause tooth stripping
- Refer to the Tooth Size chart and select the appropriate tooth size for the specific material
- Increase the band saw blade speed as recommended in the cutting chart
- Reverse the blade (turn inside out) if applicable
- Repair or replace the chip brush to ensure effective chip evacuation.
- Check the coolant flow and concentration to ensure proper application
Problem 5
Teeth Broken
Cause of the Problem
- Improper break-in
- Incorrect blade selection for the material being cut
- Workpiece spinning or moving in the vise during cutting
- Excessive feed pressure
- Hard spots in the material
- Improper handling blade when opening
Solution
- Break in the blade properly, following recommended break-in procedures for specific material
- Ensure the appropriate blade choose
- Check the workpiece clamping configuration and adjust the vise pressure as necessary.
- Reduce the feed pressure
- Inspect the material for hard inclusions that may cause tooth broken
- Ensure blade teeth no knocking on hard material when opening
Problem 6
Chip Welding at Tooth Tips
Cause of the Problem
- Insufficient coolant flow
- Incorrect coolant concentration
- Excessive speed or pressure during cutting
- Tooth size too small for the specific material
- Malfunctioning or ineffective chip brush
Solution
- Check the coolant level and ensure adequate flow to prevent chip welding
- Verify the correct coolant concentration and adjust if necessary
- Reduce the speed and/or pressure applied during cutting
- Use a band saw blade with a coarse tooth pitch for improved chip removal
- Repair or replace the chip brush to ensure proper chip evacuation.
Problem 7
Rough Cut (Washboard Surface and Vibration)
Cause of the Problem
- Dull or damaged blade
- Incorrect speed or feed settings
- Insufficient blade support
- Incorrect tooth pitch for the material
- Inadequate coolant application
Solution
- Replace the blade with a new, sharp one to eliminate cutting issues
- Increase the speed or decrease the feed rate to achieve a smoother cut
- Move the guide arms as close as possible to the work for improved blade support
- Use a band saw blade with a finer tooth pitch for a smoother cutting action
- Check the coolant flow and ensure sufficient application to reduce friction and heat built-up.
Problem 8
Wear on the Back of Band Saw Blades
Cause of the Problem
- Frozen, damaged, or worn back-up guide roll
- Excessive feed pressure
- Band saw blade rubbing against wheel flange
- Improper band tension
- Improper or insufficient coolant application
Solution
- Repair or replace the back-up roll or guide
- Decrease the feed pressure to minimize wear on the back of the blade
- Adjust the wheel cant if necessary to prevent blade rubbing
- Adjust the blade speed as recommended
- Check the coolant flow and concentration to ensure proper application
Problem 9
Wear on the gullets of Band Saw Blades
Cause of the Problem
- Excessive back-up guide preload
- Improper band tension
- Side guide adjustment too tight
- Guide arm spread to maximum
- Excessively worn teeth
Solution
- Repair or replace the back-up guide
- Adjust the blade speed as recommended
- Adjust the roller or guide
- Move the guide arms as close as possible to the work for improved blade support
- Replace new blade
Problem 10
Blade Wear - Teeth Blued
Cause of the Problem
- Incorrect band saw blade selection
- Incorrect feed or speed settings
- Improper or insufficient coolant application
Solution
- Use a band saw blade with a coarser tooth pitch to reduce heat buildup
- Increase the feed or decrease the speed to optimize cutting conditions
- Check the coolant flow and adjust as necessary to cool the blade effectively.
Problem 11
Irregular Break
Cause of the Problem
- Indexing out of sequence
- Loose material in the vise or clamp
- Guide arm spread too wide while cutting small cross sections.
Solution
- Check the machine's movement and ensure that indexing occurs in the correct sequence
- Verify that the material is securely clamped in the vise or clamp to prevent irregular breaks.
- Adjust guide arm near to material
Problem 12
Twisted Blade (Profile Sawing)
Cause of the Problem
- Blade binding in the cut
- Side guides tightened excessively
- Blade width incompatible with the radius of the cut
- Inadequate clamping of the workpiece
- Irregular coolant flow
- Excessive blade tension
Solution
- Decrease the feed pressure to alleviate blade binding
- Adjust the side guide gap to ensure proper clearance
- Use a narrower blade if the current width does not match the radius of the cut
- Check the clamping pressure to firmly hold the workpiece in place
- Inspect the coolant nozzles for proper functionality and adjust as needed
- Reduce the blade tension to prevent twisting.