Why Upgrading Is Essential for Better Bandsaw Efficiency
In the heart of any machine shop, the bandsaw stands as a workhorse, tirelessly cutting through various materials to meet the demands of a wide array of projects. In this post, we will unravel the secrets to enhancing bandsaw efficiency by introducing a new bandsaw. From optimizing blade performance to maximizing throughput, revolutionize your sawing experience and elevate your shop’s capabilities to unprecedented heights. Unlock the potential for unparalleled precision and speed with a new efficient band-sawing system.
It’s crucial to recognize the limitations that many machine shops face with their aging bandsaw models. Outdated bandsaws often struggle to keep up with modern demands. Challenges such as diminished cutting accuracy, slower cutting speeds, and increased downtime occur with increased frequency. Blade deflection and inconsistent tensioning are common issues. This results in imprecise cuts that compromise the overall quality of the parts. Moreover, the lack of advanced features, such as automated controls and integrated safety mechanisms, not only hampers operational efficiency but also poses potential risks to the operators. In a rapidly evolving machining landscape, relying on outdated bandsaws can hinder a machine shop’s ability to stay competitive and meet the ever-growing demands of precision engineering.
Advantages
Upgrading to a new machine for improving bandsaw efficiency in a machine shop brings a multitude of advantages. First and foremost, modern bandsaws are designed with cutting-edge technologies that significantly enhance cutting precision. The introduction of advanced materials and blade technologies ensures cleaner and more accurate cuts. This reduces the need for extensive post-processing. Improved cutting speeds and efficiency are notable benefits, translating to higher productivity and faster job turnaround. Additionally, many new bandsaws come equipped with automated controls, simplifying operation and minimizing the risk of errors. Enhanced safety features also contribute to a secure working environment, protecting both the equipment and the operators. Overall, the adoption of a new bandsaw marks a transformative step for any machine shop. It brings them towards elevating the performance and competitiveness.
New Technology in Improving Bandsaw Efficiency
New technology installed on bandsaws from KAAST include material height sensors, independently controlled dual flood coolant, and servo-motor controlled roller vices (on fully automatic bandsaws). These simple devices limit the head of the bandsaw from raising excessively between cuts. Instead of cycling the head and blade all the way open and closed, they are moved only high enough to allow the material to advance.
By reducing the head movement time, the efficiency of the entire cycle length is greatly improved. The dual flood coolant on new KAAST horizontal bandsaws allows for independent control of each coolant spigot. This allows operators cutting hollow shaped material to turn off the flow of coolant before the cut, while allowing it to continue to flood the blade post cut. This greatly reduces the amount of coolant that is lost into hollow material and typically found on the floor behind the bandsaw. Reducing the loss of coolant, as well as time spent cleaning coolant from shop floors, greatly improves sawing efficiency. The servo-controlled roller vices on the new KAAST fully automatic bandsaws advance materials quickly and precisely between cuts. By eliminating manual measurement of the cut length scrap is greatly reduced improving bandsaw efficiency further.
Features
The base of the new HBS automatic horizontal bandsaws are solidly welded steel and linear ways are utilized for head travel. The heavy steel base provides vibration dampening helping to decrease chattering during heavy cuts, improving cut quality and accuracy and reducing post-processing finishing. The linear ways provide smooth tracks for movement of the head as it travels up and down by utilizing dual hydraulic cylinders.
The Lenox blades of the KAAST bandsaws run through carbide inserts positioned between bearings before and after the cut. These inserts work to realign the blade and secure proper position which extends blade life and improves cut quality by maximizing material removal, even with an older blade.
The infinitely variable blade speed on new KAAST bandsaws is paired with infinitely variable down feed speed and pressure. Running from 65 to 325’/min, the variable blade speed can be adjusted to maximize chip removal. The hydraulically controlled down feed and feed pressure is adjusted to maximize cut quality. The ability to dial these three factors independently allows for maximum efficiency for all material types. On the new HBS A HQ models from KAAST, automatic hydraulic blade tensioning and monitoring work together with automatic deflection sensors. These features allow operators to set warning and shut-down parameters to ensure accuracy. This reduces scrap and maximizes blade life.
Automation
Automation options for KAAST bandsaws include vice fed and shuttle fed automatic saws as well as motorized infeed and outfeed tables. Vice fed saws either utilize a servo motor to control rollers in the vice or a physical limit switch. The servo motor option allows for multiple different lengths and cut quantities to be programmed in. Alternatively, the physical limit switch must be reset for length by the operator between changes. The shuttle fed bandsaws from KAAST utilize a servo motor driven shuttle vice which opens, moves back along the material, and clamps before pushing the material forward into the cutting envelope. In new fully automatic mitering saws from KAAST, multiple different lengths can be programmed in. Although, on some machines the angle must be set by the operator between changes. However, on the new HBS A HQ full CNC bandsaws from KAAST, operators utilize an intuitive touchscreen control which can store up to 100 programs.
This new model allows all parameters (blade speed, down feed, etc) to be set by the controller. Basing the settings on blade, material, and material profile, the controller maximizes both time and material efficiency. Motor driven infeed and outfeed tables greatly increase the scope of what a new bandsaw can cut. Solid stock of any dense material with a measurement over 12″ quickly becomes unwieldly due to the weight. The ability to support and convey long, heavy, stock though the cutting envelope rounds out the automation improvements offered by a new bandsaw.
Safety when improving bandsaw efficiency
Safety features on new bandsaws have improved dramatically in the recent past. Bandsaws are powerful machines that can pose serious risk if not equipped with the latest in safety features. New bandsaws come equipped with blade guards, wheel brakes, and safety locks on doors and moveable parts. Blade guards should extend to cover all but the cutting envelope. On older bandsaws, it is common for these guards to either partially or completely be removed during routine maintenance. Unfortunately, it is also common to fail to reinstall this important safety feature.
New bandsaws offer accordion style blade guards which eliminate the need for removal during maintenance. Also common on older bandsaws is a lack of wheel brake. Without this advancement in safety, the wheels driving the blade continue to spin if the blade breaks. The wheel brake stops the wheels from turning when activated by a broken blade detection system. This tension-based switch immediately stops the machine when a blade breaks and releases the tension. This eliminates the risk of the blade being thrown across the shop, as is known to happen with older bandsaws lacking this feature.
Safety interlocks are another improvement offered by new bandsaws. These electronic switches are installed on all hinged or movable parts. They prevent operators from being harmed by the parts they protect. The saw cannot run unless the doors are closed and the switch is activated. Combined, these and the other safety features available on new bandsaws will decrease operator risk and thus improve bandsaw efficiency.
Training, Service, and Spare Part Availability
Finally, training, service, and spare part availability are probably the most important reasons behind deciding to replace an aging machine and improving bandsaw efficiency. The necessity for training can be seen in the swiveling vise featured on KAAST’s semi-automatic bandsaws. This small relatively hidden feature of these new bandsaws adds mitering abilities when floor space is sufficient. Receiving proper training on the use and maintenance of your new saw from a professional bandsaw service technician helps to ensure that your investment will be utilized to its full potential. When an aging bandsaw needs to be repaired, finding service and outdated machinery parts is frequently difficult. A new bandsaw eliminates the delays caused by this difficulty as the operator can reach out directly to the manufacturer for all their bandsaw needs.
All in all, the benefits of replacing an older bandsaw with a new bandsaw far outweigh the drawbacks. While the initial investment may sting, that will quickly be soothed by the savings from increased efficiency, precision, and safety. It also decreases waste, reduced operator injuries, and down-time.
When you’re ready to invest in the increased efficiency, precision, and safety offered by a new horizontal bandsaw, reach out to KAAST Machine Tools or visit our website, www.KAAST-USA.com.