Break In Procedure

Selecting Correct Blade

 TPI Selection Chart Speed, Feed & Coolant Chart Commen Blade Sizes



BREAK IN PROCEDURE
All new blades possess very sharp teeth edges. This causes micro features at normal cutting rate due to excess vibration.

Apply on New Blade
What is a proper break-in? Reduce the normal feed rate to 1/3 band speed to 2/3 for First 300sqcm Cutting Recommended Cutting Rate 60 Sqcm Break in cutting rate 20sqcm :

Why? This will 'hone' the teeth of the bandsaw blade and make it last longer. Think of your band saw teeth as you
would a freshly-sharpened pencil . . . the tip is easily broken when you begin to write. A band saw tooth reacts the same way. Band speed is not what breaks down the tooth tip during break-in - the pressure is.

  

 

SELECTING CORRECT BLADE
The most important aspect that should be focused upon, before the cutting process, the most appropriate cutting blade. Proper selection brings out maximum productivity and enhanced the tool life to optimum. Choosing the correct dimension and TPI in case of a band saw blade, is thus very essential. Special tooth design can be applied to achieve better result in sawing difficult-to-cut materials.


TPI Selection Chart
Cutting of tubes and profiles
Wall  Tooth pitch (TPI)
thicness  Outer diameter D of the tube (mm)
[mm] (S) 20 40 60 60 80 100 120 150 200 300 400 500 600 700 800 900 1000 1500
2 14 14 14 14 14 14 14 10/14 10/14 8/12 8/12 6/10 6/10 5/8 5/8 5/8 5/8 5/8
3 14 14 10/14 10/14 10/14 10/14 10/14 8/12 8/12 6/10 6/10 5/8 5/8 5/8 4/6 4/6 4/6 4/6
4 14 14 10/14 10/14 10/14 8/12 8/12 8/12 8/12 5/8 5/8 4/6 4/6 4/6 4/6 4/6 4/6 3/4
5 14 10/14 10/14 10/14 10/14 8/12 8/12 8/12 6/10 5/8 5/8 4/6 4/6 4/6 4/6 3/4 3/4 3/4
6 14 10/14 10/14 10/14 8/12 8/12 8/12 8/12 5/8 5/8 4/6 4/6 4/6 3/4 3/4 3/4 3/4 3/4
8 14 10/14 8/12 8/12 8/12 8/12 6/10 6/10 5/8 4/6 4/6 4/6 3/4 3/4 3/4 3/4 2/3 2/3
10   8/12 6/10 6/10 6/10 6/10 5/8 5/8 4/6 4/6 4/6 3/4 3/4 3/4 3/4 2/3 2/3 2/3
12   8/12 6/10 6/10 6/10 5/8 5/8 4/6 4/6 4/6 3/4 3/4 3/4 3/4 2/3 2/3 2/3 2/3
15   8/12 6/10 6/10 5/8 5/8 4/6 4/6 4/6 3/4 3/4 3/4 2/3 2/3 2/3 2/3 2/3 2/3
20     6/10 6/10 5/8 4/6 4/6 4/6 3/4 3/4 3/4 2/3 2/3 2/3 2/3 2/3 2/3 2/3
30         4/6 4/6 4/6 3/4 3/4 3/4 2/3 2/3 2/3 2/3 2/3 2/3 2/3 1.4/2
50             3/4 3/4 3/4 2/3 2/3 2/3 2/3 2/3 2/3 1.4/2 1.4/2 1.4/2
75                 2/3 2/3 2/3 2/3 2/3 1.4/2 1.4/2 1.4/2 1.4/2 1.4/2
100                   2/3 2/3 1.4/2 1.4/2 1.4/2 1.4/2 1.4/2 1.4/2 0.75/1.25
150                     2/3 1.4/2 1.4/2 1.4/2 1.4/2 1.4/2 0.75/1.25 0.75/1.25
200                       1.4/2 1.4/2 1.4/2 1.4/2 0.75/1.25 0.75/1.25 0.75/1.25
250                         1.4/2 1.4/2 0.75/1.25 0.75/1.25 0.75/1.25 0.75/1.25
300                           1.4/2 0.75/1.25 0.75/1.25 0.75/1.25 0.75/1.25
350                             0.75/1.25 0.75/1.25 0.75/1.25 0.55/0.75
400                               0.75/1.25 0.75/1.25 0.55/0.75
450                                 0.75/1.25 0.55/0.75
500                                   0.55/0.75
 
Constant tooth pitch Variable tooth pitch 
Contact length Tooth pitch Contact length Tooth pitch 
Up to 6mm 24 TPI Up to 30mm 10/14 TPI
Up to 10mm 18 TPI 20 - 50mm 8/12 TPI
Up to 15mm 14 TPI  25 - 60mm 6/10 TPI
15 - 30mm 10 TPI  35 - 80mm 5/8 TPI
 30 - 50mm 8 TPI 50 - 100mm 4/6 TPI
 50 - 80mm 6 TPI 70 - 120mm 4/5 TPI
 80 - 120mm 4 TPI  80 - 150mm 3/4 TPI
120 - 200mm 3 TPI 120 - 350mm 2/3 TPI
200 - 400mm 2 TPI 250 -600mm 1.4/2 TPI
 300 - 800mm      1.25 TPI 500 - 1200 mm 0.75/1.25 TPI
 700 - 3000mm    0.75 TPI 1000 - 3000mm 0.55/0.75 TPI
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Recommended blade speed, cutting rate and cooling lubricant
Material Group Din  Material Number USA  Blade Speed (M/min)            Cutting Rate (Sqcm/min) Carbide        (M/min)  Cooling Lubricant          (oil content)
Bimetal Bimetal
Dia. 100-500mm Dia. 100-500mm
                
Structural steels St 37/42 1.0037/1.0042 A 570 60 - 80 30 - 40 100 - 130 10 - 15%
  St 52/60 1.0050/1.0060 A 572 50 -70 25 -30 90 - 120 5 - 10%
Case Hardened C 10/C 15 1.0301/1.0401 1010/1016 60 - 80 30 - 40 110 -140 10 - 15%
Steels 16 MnCr 5 1.7131 5115 50 - 60 20 - 30 80 - 100 5 - 10%
  20 CrMo 5 1.7264 0 50 - 60 20 - 30 80 -100 5 - 10%
  21 NiCrMo 2 1.6523 8620 40 - 50 15 - 20 70 - 90 5 - 10%
Nitriding steels 34 CralNi 7 1.855 0 30 - 40 15 -20 45 - 60 5%
  34 CralMo 5 1.8507 A355 Cl.D 30 - 40 15 -20 45 - 60 5%
Machining steels 9 S 20 1.0711 1212 60 - 80 45 - 50 100 - 160 10 - 15%
Quenched and temp  C 35/45 1.0501/1.0503 1035/1045 50 - 70 30 - 40 90 - 120 5 - 10%
ered steels 42 CrMo 4 1.7225 4140 40 - 60 15 - 20 70 - 90 5 - 10%
  34 CrNiMo 6 1.6582 4340 30 - 40 10 - 15 70 - 90 5 - 10%
Ball bearing steels 100 Cr 6 1.3505 52100 40 - 60 20 - 40 70 - 90 3%
Spring steels 65 Si 7 1.5028 9260 H 30 - 40 12 - 14 65 - 85 3%
  50 CrV 4 1.8159 6150 30 - 40 12 - 14 65 - 85 3%
Unalloyed C 125 W  1.1663 W 112 30 - 40 12 - 14 65 - 80 3%
Tool steels C 80 W 1 1.1525 W 108 30 - 40 16 - 20 70 - 85 3%
Tool steels 125 Cr 1 1.2002 0 30 - 40 14 - 16 65 - 80  3%
for cold work X 210 Cr 12 1.208 D 3 20 - 30 10 - 12 40 - 50 dry/2%
  X 155 CrVMo 12 1 1.2379 D 2 20 - 30 10 -12 40 - 50 dry/2%
  100 MnCrW 4 1.251 1 20 - 30 6 - 8 60 - 80 3%
  90 MnCrV 8 1.2842 2 30 - 35 12 - 14 45 - 55 3%
Tool steels 40 CrMnMo 7 1.2311 0 30 - 40 15 - 30 70 - 90 5%
for hot work X 40 CrMoV 5 1 1.2344 H 13 30 - 40 15 - 30 60 - 80 5%
  56 NiCrMoV 7 1.2714 L 6 30 - 40 15 - 30 50 - 70 5%
  40 CrMnNiMo 8 6 4 1.2738 0 30 - 40 15 - 25 35 - 70 5%
High sped steels S 6-5-2 1.3343 M 2 30 - 40 15 - 25 50 - 60 3%
  S 3-3-2 1.3333 0 30 - 40 15 - 25 55 - 65 3%
  S 2-10-1-8 1.3247 M 42 30 - 40 15 - 25 45 - 60 3%
  S 10-4-3-10 1.3207 0 30 - 40 15 - 25 45 - 60 3%
  S 18-0-1 1.3355 T 1 30 - 40 15 - 25 45 - 60 3%
 
Material Group Din  Material Number USA  Cutting speed (M/min)            Cutting Rate (Sqcm/min) Carbide        (M/min)  Cooling Lubricant          (oil content)
Bimetal Bimetal
Dia. 100-500mm Dia. 100-500mm
               
Stainless steels X 5 CrNi 18 10 1.4301 304 30 - 40 14 - 16 70 - 80 10 - 15%
  X 6 CrNioTi 17 12 2 1.4571 316 Ti 30 - 35 10-12 65 - 75 10 - 15%
  X 20 Cr 13 1.4021 420 30 - 40 12 - 15 65-75 10 - 15%
               
valve steels X 45 CrSi 9 3 1.4718 HNV 3 20 - 30 10 - 12 50 - 60 10%
  X 45 CrNiW 18 9 1.4873 0 20 - 30 6 - 8 40 - 50 10%
High temperature X 12 CrCoNi 21 20 1.4971 HEV 1 20 - 25 4 - 6 30 - 40 15%
resisting steels X 20 CrMoWV 12 1 1.4935 HNV 8 25 - 35 8 - 10 30-40 15%
Heat resistant X 15 CrNiSi 25 20 1.4841 314 20 - 30 6 - 8 30 - 40 15%
steels X 12 NiCrsi 36 16 1.4864 330 20 - 25 4 - 6 30 - 40 15%
Special alloys  Nicr 19 NbMo 2.4668 Inconel 718 10 - 18 3 - 5 20 - 30 20%
  NiMo 30 2.481 Hastelloy B 15 - 20 4 - 6 25 - 35 20%
  NiCr 13 Mo 6 Ti 3 2.4662 Nimonic 901 10 - 15 3 - 4 20 - 30 20%
  NiCo 20 Cr 20 MoTi 2.465 Nimonic 840 12 - 17 3 - 4 22 - 35 20%
  X 8 CrNiAlTi 20 20 1.4847 Incoloy 840 13 - 18 3 - 4 22 - 35 15%
Tempered steels              
1000-1200 N/mmsq   -   25 - 30 3 - 4 35 - 50 ~ 5%
1200-1400 N/mmsq   -   20 - 25 3 - 4 30 -45 ~ 5%
1400-1600 N/mmsq   -   15 - 20 3 - 4 25 -35 ~ 5%
Hardened steels                 
50 HRC   -   - 4 - 6 15- 20 ~ 5%
55 HRC   -   - 4 - 6 10-15 ~ 5%
60 HRC   -   - 3 - 4 08 - 12 ~ 5%
Cast steel GS-38 1.042   40 - 50 30 - 40 70 -100 ~ 3%
  GS-60 1.0558   40 -50 20 - 25 60 -85 ~ 3%
Cast iron GG-30 0.603 A 48-45 B 40 -50 25 - 30 60 - 80 dry/2%
  GGG-50 0.705 65-45-12 35 -45 18 - 20 55- 75 dry/2%
Alloyed (NiCrMo)     20 -30 10 - 12 40 -50 dry/2%
Titanium Ti 1 3.7025 CP Titanium 20 -35 4 - 6 50-70 10%
Alloyed G - TiAl 6 V 4 3.7164 Ti-6Al-4V - - 65 -90 10%
Zirconium   -   - - 50 -70 10%
               
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Band Saw Blade Sizes Most Commonly Used in different widths
13mm Width Common Blade Sizes and Available Grade
ICON M-42 GRADE
Common Blade Size ICON M-42/TPI    
1230 x 13 x 0.65 14    
1250 x 13 x 0.65 10, 14    
1340 x 13 x 0.65 10, 14    
20mm Width Common Blade Sizes and Available Grade
ICON M-42 GRADE
Blade Size ICON M-42/TPI    
2360 x 20 x 0.9 4/6, 5/8, 6/10, 8/12    
2515 x 20 x 0.9 10/14,14    
2540 x 20 x 0.9      
2600 x 20 x 0.9      
3000 x 20 x 0.9      
27mm Width Common Blade Sizes and Available Grades
AVAILABLE IN ICON M-42 GRADE, ACE M-42 GRADE, ACE M-51 GRADE     
Blade Size ICON M-42/  TPI ACE M-42/ TPI ACE M-51/ TPI
2450 x 27 x 0.9 2/3, 3/4, 4/6, 5/8, 2/3, 3/4, 4/6, 5/8, 2/3, 3/4, 4/6
2540 x 27 x 0.9 6/10, 8/12, 10/14, 14 6/10, 8/12, 10/14, 14  
2910 x 27 x 0.9      
3000 x 27 x 0.9      
3200 x 27 x 0.9      
3375 x 27 x 0.9      
3505 x 27 x 0.9      
3660 x 27 x 0.9      
3760 x 27 x 0.9      
3800 x 27 x 0.9      
34mm Width Common Blade Sizes and Available Grades
AVAILABLE IN ICON M-42 GRADE, ACE M-42 GRADE, ACE M-51 GRADE, JAGUAR
Blade Size ICON M-42/ TPI ACE M-51/ TPI ACE M-51/TPI JAGUAR ASP MATERIAL/ TPI
3505 x 34 x 1.1 2/3, 3/4, 4/6, 5/8, 2/3, 3/4, 4/6 2/3, 3/4
3720 X 34 X 1.1 6/10, 8/12    
4100 x 34 x 1.1      
4160 X 34 X 1.1      
4570 x 34 x 1.1      
4640 x 34 x 1.1      
4860 x 34 x 1.1      
41mm Width Common Blade Sizes and Available Grades
AVAILABLE IN ICON M-42 GRADE, ACE M-42 GRADE, ACE M-51 GRADE, JAGUAR
Blade Size ICON M-42/ TPI ACE M-51/ TPI ACE M-51 /TPI JAGUAR ASP MATERIAL/ TPI
4570 X 41 X 1.3 1.4/2, 2/3, 3/4, 4/6, 5/8, 2/3, 3/4, 4/6 2/3, 3/4
4670 X 41 X 1.3 6/10    
4860 X 41 X 1.3      
5450 X 41 X 1.3      
5800 X 41 X 1.3      
6900 X 41 X 1.3      
       
       
       
41mm Width Common Blade Sizes and Available Grades
AVAILABLE IN ICON M-42 GRADE, ACE M-42 GRADE, ACE M-51 GRADE, JAGUAR
Blade Size ICON M-42/ TPI ACE M-51/ TPI ACE M-51/TPI JAGUAR ASP MATERIAL/ TPI
6600 X 54 X 1.6 1.4/2, 2/3, 3/4 1.4/2, 2/3 1.4/2, 2/3
6900 X 54 X 1.6      
7600 X 54 X 1.6      
8000 X 54 X 1.6      
8800 X 54 X 1.6      
67mm Width in blade size available
ICON M-42 GRADE, ACE M-42 GRADE, ACE M-51 GRADE, JAGUAR
Blade Size ICON M-42/ TPI ACE M-51/ TPI ACE M-51/TPI JAGUAR ASP MATERIAL/ TPI
6600 X 54 X 1.6 0.75/1.25, 1.4/ 2, 2/3, 3/4 0.75/1.25, 1.4/ 2, 2/3 0.75/1.25, 1.4/ 2, 2/3
8000 X 67 X 1.6      
8800 X 67 X 1.6      
10600 X 67 X 1.6      
11880 X 67 X 1.6      
12300 X 67 X 1.6      
13900 X 67 X 1.6      
80mm Width in blade size available
ICON M-42 GRADE, ACE M-42 GRADE, ACE M-51 GRADE, JAGUAR
Blade Size ICON M-42   ACE M-51  
12300 X 80 X 1.6   ICON M-42/ 2 / TPI ACE M-51/ 2 / TPI  
13900 X 80 X 1.6      
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