Introduction to metal band saw blades
Metal band saw blade is an efficient and precise metal cutting tool made of continuous metal strip, with a closed-loop structure formed by welding at both ends, widely used in the field of industrial manufacturing. Its core feature lies in achieving stable cutting of high hardness materials through material composite and process optimization. The following is an explanation from four dimensions: structural characteristics, classification, application scenarios, and production processes:
1、 Structural characteristics
Bimetallic composite structure
Tooth material: High speed steel (such as M42, containing 8% cobalt) or hard alloy is used, with a hardness of HRC67-69, ensuring wear resistance and high temperature resistance (stable performance below 500 ℃) .
Back material: Low alloy spring steel (such as B318) is commonly used, with a fatigue strength of ≥ 980MPa, providing support and vibration resistance.
Welding process: Seamless bonding between teeth and back is achieved through laser welding or electron beam welding, with a weld strength greater than 400N/mm ² to avoid stress cracking .
Serrated design
The tooth profile is divided into standard teeth, jumping teeth, tensile teeth, etc., to meet the cutting needs of different materials (such as coarse teeth for soft metal and fine teeth for high-precision machining) .
Some high-end products use passivation treatment or titanium nitride (TiN) coating to reduce friction coefficient and extend service life .
2、 Main categories
Divided by material
High speed steel band saw blade: suitable for ordinary metals (structural steel, aluminum alloy, stainless steel, etc.), with high cost-effectiveness and stable cutting efficiency .
Hard alloy band saw blade: containing superhard coatings such as tungsten carbide, specifically designed for high hardness materials (such as high-temperature alloys and titanium alloys), with wear resistance increased by more than three times .
Divided by Function
Universal type: Suitable for continuous cutting of most metal materials (such as 45 # steel, weathering steel)
Special types: such as food grade passivated saw blades (to avoid metal contamination), anti vibration saw blades (for mining machinery), etc.
3、 Application Fields
Industrial manufacturing
Mechanical processing: Cutting high hardness components such as bearing steel and mold steel, with an accuracy of ± 0.1mm and a surface roughness of ≤ Ra3.2 μ m
Automotive and Aerospace: Used for precision machining of aluminum alloy frames and titanium alloy engine components .
Special Scene
Nuclear power and rail transit: Cutting heat-resistant steel and stainless steel pipes to meet the requirements of corrosion resistance and high strength.
Wood processing (requiring special treatment): By optimizing the tooth profile, wood fiber tearing is reduced, but the efficiency is lower than that of specialized woodworking saw blades
4、 Production process flow
Material Handling
Edge cutting: Cold rolled alloy steel strip is flattened with a hard alloy blade on the welding surface, and the other side is processed into an arc-shaped back bottom
Cleaning: Remove impurities from the welding surface to prevent weld inclusions or porosity defects
hybrid welding
Laser welding: High precision welding of high-speed steel and spring steel is completed in a vacuum environment, with a small heat affected zone, suitable for ultra narrow saw blades (such as 13mm wide)
surface strengthening
Coating treatment: A wear-resistant layer such as titanium nitride is formed through physical vapor deposition (PVD) to extend the lifespan of the teeth
Passivation treatment: for the food and medical fields, to avoid metal ion migration and pollution.
5、 Core advantages
Efficient cutting: The feed rate can reach 65mm/min (for cutting Φ 200mm steel bars), and the efficiency is increased by more than 40% compared to traditional saw blades
Long life design: M42 high-speed steel saw blade can continuously cut stainless steel for 300 minutes without teeth, reducing the cost per meter by 42%
Wide adaptability: covering the entire material spectrum from soft metals (aluminum) to superhard alloys (SKD11 mold steel) [1] [4].
Summary: Metal band saw blades have become the core tool for efficient cutting in modern industry due to their bimetallic composite structure, precision manufacturing process, and diverse tooth design. When purchasing, the appropriate model should be selected based on parameters such as material hardness (recommended hard alloy coating for stainless steel), cutting accuracy (fine teeth for ± 0.1mm requirements), etc.
1、 Industrial manufacturing field
Mechanical Processing and Automotive Manufacturing
Core component processing: used for cutting automotive parts such as engine cylinder heads and gearbox housings, with a cutting accuracy of ± 0.1mm and a cross-sectional roughness of ≤ Ra3.2 μ m, meeting high-precision assembly requirements.
Material adaptability: It can efficiently cut lightweight materials such as aluminum alloys and magnesium alloys, and is suitable for the processing needs of structural components in new energy vehicles.
Consumables attribute: Due to frequent use, bimetallic band saw blades are highly efficient consumables in automotive production lines, with an annual replacement volume of millions.
Mold and Special Steel Processing
High hardness material cutting: For materials with hardness ≥ HRC60 such as mold steel (SKD11) and bearing steel (GCr15), hard alloy band saw blades can increase cutting life by more than 3 times .
Complex profile processing: Suitable for forming and cutting complex workpieces such as irregular steel pipes and gear blanks, reducing subsequent precision machining processes.
2、 Energy and Infrastructure Construction
Aerospace and Rail Transit
Titanium alloy cutting: used for machining key components such as aircraft engine blades and high-speed rail bogies, maintaining the stability of the material's metallographic structure during the cutting process.
Application of heat-resistant steel: Cutting stainless steel pipes (such as 304L/316L) in nuclear power equipment to meet the requirements of corrosion resistance and high precision .
Wind and nuclear power fields
Large forging processing: cutting ultra large diameter components such as wind turbine spindles (42CrMo4) and nuclear power flanges (SA-508), with a single cutting diameter of up to Φ 1.2m.
Requirement for anti fatigue performance: Reduce the risk of vibration fracture and ensure equipment safety through a bimetallic composite structure (high-speed steel+spring steel).
3、 Special Materials and Emerging Industries
Cutting of difficult to process materials
High temperature alloys: For continuous cutting of aerospace materials such as Inconel 718 and Hastelloy, hard alloy coated saw blades are required .
Nonferrous metals and non metals: Suitable for low stress cutting of materials such as copper alloys and graphite electrodes, with no edge defects on the surface .
Extension of new manufacturing scenarios
Commercial Aerospace: Used for efficient cutting of thin-walled aluminum alloy components (thickness ≤ 3mm) for rocket fuel storage tanks.
Medical equipment: Food grade passivated saw blades are used for processing medical titanium alloy implants to avoid metal contamination.