Performance evaluation of bandsaw using scientific method when cutting tool steels

Bandsawing is a key primary machining operation for cutting off raw material into required dimensions, which is subjected to further secondary machining operation(s) to manufacture a product or a component. Bandsawing is distinctively characterised from other multipoint cutting operations with small depth of cut or feed per tooth (5 μm - 50 μm) compared to the cutting edge radius (5 μm - 15 μm). Bandsawing performance significantly differs depending on workpiece material characteristics. In the current investigation, performance of bandsawing operation has been scientifically evaluated when cutting two different tool steel materials (Orvar Supreme and Sverker). Bandsawing tests were carried out with 6 different cutting speeds ranging from 31 m/min to 90 m/min and four different depths of cut ranging from 1 μm to 4 μm. Cutting forces and thrust forces were continuously measured throughout the cutting tests. Specific cutting energy parameter calculated based on cutting force and material removal data has been used to quantitatively measure the efficiency of the metal cutting process at different feeds and speeds. The bandsaw teeth at the worn condition have been studied under a Scanning Electron Microscope to identify wear modes and mechanisms. The chip characteristics at different feeds and speeds have also been discussed. The sawing community including bandsaw end users and design engineers should find the results presented of interest.