Challenge

A forging company(hereinafter referred to as the "customer") working with round bars grades 42CrMo and 45# reported ineffective cutting operation from brands currently in use, experiencing body breakage and cracks on the back edge.

42CrMo steel is ultra-high-strength steel with high strength and toughness. It is used to manufacture forgings that require higher toughness and larger quenched and tempered section than 35CrMo steel. The 45# round bar is a high-quality carbon structural steel with good cold and hot workability and good mechanical properties.

Observation

BICHAMP engineers determined the following conditions:

    1. Proper machinery maintenance was not in place, many signs of aging equipment.

    2. The material was complicated and there were many odd-shaped parts.

    3. Materials were forged and then sawed. The cutting surface was relatively large and the internal toughness distribution was uneven.

*Materials on the Site

Solution

In view of the different materials and poor working conditions, especially a large number of forgings, We proposed to use TANCUT saw blades for trial cuts TANCUT is suitable for cutting large to medium-sized difficult-to-cut materials. It has proven itself working with die steel, alloy steel, stainless steel, and tool steel.

Engineers adjusted machinery running parameters and provided on-site training for the operators.   

*Material Hard Spots Resulting in Saw Blade Tooth Stripping

Sawing parameters

Sawing Machine: Snyder GK42100

Saw Blade Series: HB 67-1/1.5-9860 X 2

Linear Speed: 25-33m/min (line speed gradually increases)

Feed Speed: 5mm/min

Cutting Fluid: Coolant concentration 5%

"When the tooth encounters a hard point, the additional friction will cause tooth chipping. Continuing cutting at the same spot will cause the stripping which can destroy the blade. Generally speaking, we do recommend making a new cut 10mm away" one of the engineers said.

After a new cut, the cutting progressed smoothly. In the end, TANCUT band saw blade cut a total of 25 shifts, 10.85 square meters, with continuing cutting capacity.