Boost Your Sawing Operations
Sawing system innovations deliver faster, more accurate and consistent cuts, even in exotic metals. The post Boost Your Sawing Operations appeared first on Fabricating & Metalworking.
The latest advancements in sawing technology, as well as streamlined and balanced feed rates and faster cutting rates, result in increases in both throughput and profits.
Space-saving Innovation: A Fully Automatic System for Processing
For metalworking companies facing limited space challenges, KASTO Inc. (Export, PA) introduces a revolutionary solution that fully automates sawing, sorting, and storage processes around the clock. The new KASTOsort tower integrates seamlessly with high-performance saws such as the KASTOvariospeed or KASTOtec — with or without dedicated sorting robots — enabling efficient, order-specific sorting immediately after cutting.
This innovative system combines band or circular saw, a sorting robot, and a compact storage solution into one cohesive unit, requiring just over 120 square feet for medium-format storage. By maximizing vertical space and ensuring high storage density, the tower offers quick access and flexible material intake — all while saving valuable floor space.
The fully automated operation allows continuous sawing without delays for manual box changes. A versatile lifting beam equipped with a three-Euro-pallet support works in tandem with a drive-through station, ensuring seamless transfer of customized load carriers for prompt pick up, e.g., a forklift.
Powered by the ProControl system and managed via the KASTOlogic mobile app, the KASTOsort tower guarantees fast, error-free operations and real-time process tracking. KASTO also tailors the solution to each customer’s unique requirements, providing a robust, space-saving, and highly productive system for modern metalworking facilities. This pioneering concept not only streamlines production but also reinforces KASTO’s commitment to delivering innovative, customer-centric solutions with excellence.
New Pulse Cutting Technology for Faster, More Consistent Cuts
Amada Machinery America (Brea, CA) has launched its latest production cutting innovation, the PCSAW430AXII Pulse Cutting Saw. This advanced machine offers cutting capacities for round and square bars from 1.18”-to-16.93” and incorporates pulse cutting technology for faster cutting rates and unmatched precision.
The new Pulse Saw uses pulse-controlled technology to reduce vibrations, ensuring smoother, more consistent cuts, boosting productivity and efficiency for manufacturers and fabricators.
Key features of the PCSAW430AXII include:
- Eco pump technology to lower energy consumption.
- A larger 21” control panel (up from 12.1”) for easier operation.
- A new servo feeding system with an updated minimum cutting length of 5 mm for greater precision.
For optimal performance, Amada Machinery recommends pairing the Pulse Saw with the AXCELA G Carbide Tipped Blade, designed for high-speed cutting of tough materials. The AXCELA G blade features a kerf-dispersal tooth shape and micro-chamfer tip, enabling faster cuts without compromising quality.
Servo-driven Precision Down Feed Control Ensures Faster Cutting Rates
Behringer Saws, Inc.’s (Morgantown, PA) HBE Dynamic horizontal band saw combines innovative features to enhance performance, precision and user convenience, all while prioritizing safety. Its unique cast iron dual column construction frame provides exceptional rigidity, reducing vibration and enhancing blade tension, resulting in superior cutting accuracy. Two linear ways and four sets of bearings ensure precise vertical blade movement, while the horizontal band arrangement and hydraulically tensioned blade, guided by double roller bearings, further improve cutting precision.
One of the standout features of the HBE Dynamic is its servo-driven precision down feed control. This system automatically adjusts blade pressure, balancing feed rate and pressure for improved cut quality, faster cutting rates and longer blade life. Additionally, the electrically powered ball screw-driven material feed gripper eliminates backlash, ensuring precise material positioning.
The automatic feed control adjusts cutting parameters, such as blade speed and down feed rate, to suit material grade and shape. This enables flexible material programs and enhances productivity, while a fault history feature provides detailed alerts in plain text for better planning and analysis.
The saw’s high-torque, frequency-controlled blade drive is energy efficient yet delivers the power and speed needed for optimal throughput. The enclosed design ensures operator safety, keeps the workspace clean, and reduces noise, while the intuitive NC control system ensures easy operation.
The HBE Dynamic is available in five models (261A, 321A, 411A, 511A, 663A) with a cutting range of up to 26.0” diameter for round stock and up to 28.0”-x-26.0” for flat stock.
Game-changing, Precision Cutting Structural Band Saw
DoALL Sawing Products (Savage, MI) offers the groundbreaking DCDS-340CNC-X Structural Band Saw. This state-of-the-art machine is a precision engineering marvel that elevates your cutting experience. “Precision is not just a measure for us; it’s a promise,” said Steve Yulga, director of sales and marketing, DoALL Sawing Products. “The DCDS-340CNC-X is more than a machine; it’s a leap into the future of precision cutting.”
This structural band saw features three game-changing elements:
- Unparalleled precision:
- Servo-driven swivel head with Tilt angles up to 60° right and 45° left for versatile cutting.
- Siemens controls with touch screen panel for user-friendly interface for seamless job programming and real-time monitoring.
- Efficiency redefined:
- Automatic and semi-automatic cycles enable adaptability to various cutting requirements, ensuring optimal efficiency.
- Direct driven band drive features VFD-controlled motor for reliable and efficient cutting without belt slippage.
- Productivity amplified:
- Multiple machine cycles operate seamlessly in both semi-automatic and automatic modes for enhanced productivity.
- Nesting fixtures and multiple angle control increase productivity in applications like bullnose cuts and stair tread production.
Operational advantages include:
- Hydraulic band tension maximizes cutting rates and extends band life.
- Flood coolant system results in straighter cuts and prolonged blade life.
- Modified feed system enables precise cutting feed rates for accuracy.
Dual-column Automatic Band Saw: Accurate High-capacity Production
HE&M Saw’s (Pryor, OK) DC22A is a dual-column band saw designed for cutting exotic metals such as Inconel and tool steels like D2. The saw uses a 2” blade with a cutting capacity of 22” W-x-22” H. HE&M Saw’s dual-column band saws are engineered for precision, durability, and heavy-duty performance, making them an industry leader in metal-cutting solutions. Built in the United States, these saws are renowned for their ability to handle high-capacity production while maintaining accuracy and efficiency.
Key features include a rigid dual-column design, which ensures stability and minimal vibration during operation, even when cutting large or tough materials. Advanced servo-controlled systems enhance cutting performance by optimizing blade feed rates, reducing human error, and extending blade life. Touchscreen controls and integrated material libraries simplify operation, allowing users to achieve consistent results across a variety of applications.
The columns on the newer dual column models are now constructed of structural tubes rather than the fabricated columns creating a stouter arm configuration. The column chains have been replaced with linear rails for less arm side-play, which substantially increases blade life and creates a smoother running machine.
The DC22A comes standard with a twin ballscrew bar feed that is servo-driven creating faster cycle times and is more accurate in positioning the material. This allows for improved efficiency and more accurate part lengths. The feed stroke is 0”-to-48” with multiple indexing for longer part lengths with an option to upgrade to a 0”-to-120” stroke feed.
High Productivity Blades Deliver Longer Life for Hard-to-Cut Materials
MC7 carbide band saw blades from L.S. Starrett Co.The L.S. Starrett Co. (Athol, MA) offers Advanz MC7 carbide band saw blades for high productivity and longer life when cutting hard materials. The Advanz MC7 utilizes a progressive four-tooth grind that creates seven distinct chips. The end result is less wear when compared to blades with conventional triple chip tooth formation. The four-tooth grind is effective on nickel alloys, stainless and “tough-to-cut” tool and heat-treated steels.
The Advanz MC7 features exclusive Starrett tooth geometry that has a progressively ground trapezoidal tool design and positive rake angle. The blade is made of sub-micron grain carbide (HV1600). Advanz MC7 blades offer precision cuts for a superb surface finish and provide excellent “cost-per-cut” for production sawing. The exclusive Starrett edge preparation minimizes micro chipping.
Advanz MC7 band saw blades are ideal for solids and bundles of solids. Blades are offered in multiple sizes in widths from 1-1/4″-to-2-5/8″ (34 mm-to-67 mm) and thicknesses from .042″-to-.063″ (1.10 mm- to-1.60 mm).
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