Instrument and equipment for wood processing

Transcription

1 Instrument and equipment for wood processing

2 BAND SAW BLADES CATALOGUE BAND SAW BLADES FOR WOOD PROCESSING 1 WIDE BAND SAW BLADES 7 FRAME SAWS 8 BAND SAW BLADES FOR FOOD PROCESSING 9 TABLE OF BAND SAW BLADES STANDARDS 10 ABRASIVE SHARPENING WHEELS 11 CBN SHARPENING WHEELS 12 SHARPENING MACHINE FOR BLADES 13 TOOTH SETTER FOR BLADES 15 SAWMILL HORIZONTAL DEVICE 17 CROSS-CUTTING MACHINE 19 EDGE-TRIMMING MACHINE 20 ROLLERS, INDICATORS AND MANOMETERS 21 BEARINGS AND BELTS 22 LUBRICATING FLUIDS (LCF) 23 RECOMMENDATIONS ON THE USE AND TECHNICAL SERVICING OF LENKER SAWS 24 MISTAKES IN PREPARING OF BAND SAW BLADES 31 METHODS FOR DEALING WITH PROBLEMS 32

3 LENKER Standard BAND SAW BLADES FOR WOOD For cutting natural wood Saw bench: Saw benches for cutting logs Tooth profile: 10/30 N unprocessed ROH with tooth setting, sharpening, hardened teeth RO - with tooth setting, sharpening, without hardened teeth LENKER Standard - low-cost band saw blades for cutting logs. You receive quality cutting of raw with good proportion: saw price/sq.m. of sawing production. LENKER Standard is made of steel alloy hat conforms with standards of wood processing industry. The backside of the saw is also rounded and surface is gray and blue color. LENKER Standard saws are universal and are perfect for sawing any wood, including softwood and hardwood, frozen and dry logs. The technology of production includes the hard-tempering of every tooth using method of electromagnetic induction that increases the life cycle of a in many times. LENKER Standard band saw blades demonstrate the result of cutting under 40 sq. m. of wood. The blades are available for delivery with tooth setting, sharpening, hardened teeth. The blades are supplied in rolls or welded at order according to the type of saw bench, hardness of the material is HRC (hardness of hardened teeth is 62-65HRC). Band saw blade type Dimentions H x S, mm LENKER Standard 35x1,0 LENKER Standard 40x1,0 LENKER Standard 50x1,0 1

4 LENKER BAND SAW BLADES FOR WOOD For cutting natural wood Saw bench: Saw benches for cutting logs Tooth profile: 10/30; 9/29 N - unprocessed ROH with tooth setting, sharpening, hardened teeth RO - with tooth setting, sharpening, without hardened teeth Band saw blade is made of high-quality German steel, that makes it hardness and flexibility at the same time. It can handle double workload as opposed ones. It is made of 51 CrV4 highspeed steel, that is doped with chromium, nickel and vanadium. The color of the steel is yellow. LENKER is an optimal combination of hardness and flexibility. It has polished surface of a blade. Its backside is rounded. Tooth profile is made by cold stamping method, through its flexibility saw has a long life cycle, a saw tooth can be sharpened and dragged for many times without damage of resistance of tooth. LENKER band saw blades demonstrate the result of cutting under 60 sq. m. of wood. The blades are available for delivery with tooth setting, sharpening, hardened teeth. The blades are supplied in rolls or welded at order according to the type of saw bench, hardness of the material is HRC (hardness of hardened teeth is 62-65HRC). Band saw blade type Dimentions H x S, mm LENKER 35x0,9 LENKER 35x1,0 LENKER 40x1,0 LENKER 50x1,0 2

5 HAMMER BAND SAW BLADES FOR WOOD For cutting natural wood Saw bench: Saw benches for cutting logs Tooth profile: 10/30 N - unprocessed ROH with tooth setting, sharpening, hardened teeth RO - with tooth setting, sharpening, without hardened teeth HAMMER band saw blades are made of high-quality steel that ensures combination of hardness and flexibility and provides durability of instrument without cracks, that certainly causes early tearing of a blade. The material has high resistance and hardness after hardening of teeth and provides durability at work even after many sharpening. The backside of it is rounded. Its thickness is increased for better integrity of a blade that prevents burrs on the backside of a saw and removes inner pressure of blade. The rounding provides better quality of sawing process, protects the pulley surface. The surface of the saw is polished and lubricated against corrosion. Under the right conditions of use HAMMER band saw blades demonstrate the result of cutting under 65 sq. m. of wood. The blades are available for delivery with tooth setting, sharpening, hardened teeth. The blades are supplied in rolls or welded at order according to the type of saw bench, hardness of the material is HRC (hardness of hardened teeth is 62-65HRC). Band saw blade type Dimentions H x S, mm Hammer 35x1,07 Hammer 38x1,07 Hammer 40x1,07 Hammer 50x1,07 3

6 LENKER Premium BAND SAW BLADES FOR WOOD 4 For cutting frozen wood, deadwood and hardwood. Saw bench: Saw benches for cutting logs Tooth profile: 10/30; 9/29 N - unprocessed ROH with tooth setting, sharpening, hardened teeth RO - with tooth setting, sharpening, without hardened teeth LENKER Premium is used for cutting soft, medium, hard and frozen wood according to a tooth profile at band saw blade benches for wood or sawmills. It is made of D6A alloy laminated spring steel that combine hardness and plasticity. The saws of D6A steel can saw 10-20% of sawlogs more than C75 steel before sharpening. The quantity of sharpening is limited by length of hardened part of tooth to times, at high quality saw preparation to 25 times. Additional advantage of saws that are made of D6A steel is a better resistance of cutting a sawlog at difficult conditions. The quantity of cut sawlog within sharpening is 2-3 m 3. Description: the blades are available for delivery with tooth setting, sharpening, hardened teeth, supplied in rolls or welded at order according to the type of saw bench, material is D6A steel the hardness of the material is HRC (hardness of hardened teeth 57 HRC). Band saw blade type Dimentions H x S, mm LENKER Premium 32x1,1 LENKER Premium 35x0,9 LENKER Premium 35x1,0 LENKER Premium 35x1,1 LENKER Premium 40x1,0 LENKER Premium 50x1,0 LENKER Premium 50x1,1

7 BI-METAL BAND SAW BLADES FOR WOOD For cutting natural wood Saw bench: Saw benches for cutting logs Tooth profile: 10/30 RO - with tooth setting, sharpening, without hardened teeth Highly efficient hard-alloyed saw blades is one of the latest development in the world. Directed toward by special method hard-alloyed teeth of a saw have certain rotated geometry that provides optimal emission of chip and high productivity. Designed geometry of the teeth of Lenker hard-alloyed saw blades helps to receive clear and soft surface of a cut without vibrating. Quality control warranty high at stable quality of a tool and provides the best saw values of productivity, resistance to wearing and accuracy. Blade is used for hard, frozen and exotic types of wood. Bi-metal band saw blades are made of 2 types of steel: high-speed steel M2, that is used for cutting part of a saw and is HRC hardness; the basis is made of D6A alloy laminated spring steel HRC hardness. Two types of steel are connected by electronic bunch and a heat processing at special oven after. Band saw blade type BI-METAL BI-METAL BI-METAL Dimentions H x S, mm 35x0,9 RO M 2 BM 35x1,0 RO M 2 BM 35x1,1 RO M 2 BM 5

8 JOINER NARROW BAND SAW BLADES FOR WOOD JOINER is a narrow band saw blade (joiner) made of high-quality German steel that provides hardness and flexibility of a blade at the same time. JOINER band saw blades can handle two times more workload than other ones. Service conditions: The maximum speed of cutting of a blade is fixed by manufacturer. It is from 20 to 35 m/s. The general principle is spreading: as harder is a material as lower is speed. The blades are available for delivery with tooth setting, sharpening, hardened teeth. The blades are supplied in rolls or welded at order according to the type of saw bench, hardness of the material is HRC (hardness of hardened teeth is 62-65HRC). Band saw blade type For cutting at joiner s. Saw bench: Vertical type joiner sawmills ROH with tooth setting, sharpening, hardened teeth RO - with tooth setting, sharpening, without hardened teeth Dimentions H x S, mm JOINER narrow band saw blade 10x0,6 JOINER narrow band saw blade 10x0,7 JOINER narrow band saw blade 15x0,6 JOINER narrow band saw blade 15x0,7 JOINER narrow band saw blade 20x0,7 JOINER narrow band saw blade 25x0,7 JOINER narrow band saw blade 30x0,7 6

9 LENKER WIDE BAND SAW BLADES For cutting logs of a big diameter. It is possible to braze a stellite. Band saw blade type LENKER wide band saw blade LENKER wide band saw blade LENKER wide band saw blade LENKER wide band saw blade LENKER wide band saw blade LENKER wide band saw blade LENKER wide band saw blade b x S x t, mm steel 80x1,07x22 80x1,07x35 100x1,07x22 100x1,07x35 100x1,07x40 110x1,1x35 110x1,1x40 7

10 LENKER FRAME SAWS (KV) tooth with с broken backside surface For processing of hard and softwood while order You should inform the type of sawing wood. Presentation: Machinery saw blades are supplied milled and hardened. Completing: It is supplied with hardened bars 35, 30, 25 mm width, with jagged bars, straight perforating (ESTERER) or wiout bars. планками. Dimentions Tooth pitch Saw blades are made of 75Crl (DIN ) material 46+/-2 HRc hardness. We make a surfacing and sharpening of stellite on Vollmer benches. Blades are made with the quantity of teeth and end undercut according the rules or on request. Also it is possible to produce other types of teeth (pitch and shape) and other types of bars and additional holes for fixing. 140x1,8 140x2,0 140x2,2 160x2,0 160x2,2 180x2,2 180x2, The main advantages of the saws with stellite are: 1. The stability of cutting edge is more (in 5-10 times more comparing with classic modification) 2. Power consumption at sawing is lower. 3. Lower predisposition to breaking of cutting edge influenced by pollution. (comparing with TS tools). 4. The quality of a sawing surface of a material is better. 5. Higher accuracy of size and shape of sawing material. 6. The adaptation ability of cutting edge geometry according these conditions (bench type, type of logs, regime of cutting and etc) 7. Under the influence of higher cutting ability (the ability of entering to material) lower heat tension of cutting edges at sawing. 8. It is possible to repeate a surfacing of cutting edges of tool after sharpening the whole surfacing coat (after about sharpening). 9. Downtime for changing tools is lower influenced by its blunting. 10. Increasing of bench productivity by increasing of giving at replacement of tooth setting saws. 8

11 LENKER BAND SAW BLADES FOR FOOD PROCESSING For cutting meat, fish and bones. ROH with tooth setting, sharpening, hardened teeth RO - with tooth setting, sharpening, without hardened teeth LENKER band saw blades, for cutting: - meat - fish - bones The saws are used for cutting frozen meat with bones to receive straight and soft cut at sawing. Products don t crumble and have attractive condition for buyer. LENKER band saw blades are developed and complied with using the latest machinery and conform to the highest requirements. They differ in mechanical durability, high quality and easiness in service. Band saw blade type Dimentions H x S, mm Tooth pitch t, mm LENKER band saw blades for food processing 16x0,6 6,35 LENKER band saw blades for food processing 19x0,7 8,00 9

12 TABLE OF BAND SAW BLADES STANDARDS We suggest the following table of the length of band saw blades taking into account tooth pitch of 22,2 mm and quantity of teeth. The length multiple of 3 is highlighted, that is needed according to the conditions of tooth side clearance (right left straight). 10

13 HD METALDRAFT ABRASIVE WHEELS Depending on type of the blank and working conditions we produce sharpening wheels with different technical properties and recipes for sharpening of band, frame and circular saw blades. Our sharpening wheels are used at universal and CNC cutting machines. FOR SHARPENING OF BAND SAW BLADES Production Dхdхs (тт) abrasive wheel abrasive wheel abrasive wheel abrasive wheel abrasive wheel 127x12,7x6 150x32x6 126x12,7x5 150x32x8 175x32x6 Type HD MetalDraft abrasive wheel HD MetalDraft abrasive wheel HD MetalDraft abrasive wheel HD MetalDraft abrasive wheel HD MetalDraft abrasive wheel HD MetalDraft abrasive wheel HD MetalDraft abrasive wheel HD MetalDraft sharpening cup Dimentions, mm 125x6/4/2x12,7 150x6x32 150x6/4/2x32 175x6x32 200x6/4/2x32 200x6/3/3x32 250x10/7/3x32 100x50x20 11

14 CBN SHARPENING WHEELS (WITH DIAMOND COVERING) For sharpening of band saw blades Production Dxd, mm CBN WHEEL 127x12,7 CBN WHEEL 127x32 CBN WHEEL 150x20 CBN WHEEL 203x32 12

15 GМ-2 SHARPENING MACHINE FOR BLADES For automatic sharpening of band saw blades using special CBN wheel. The construction of the sharpening machine is able to grind saws 50 mm thickness with high quality and durability. Tooth profile exactly is in line with sharpening wheel profile. In the process of sharpening of the saw the lubricating fluid is supplied to the cutting area. Specifications Value Voltage 380 V (220 V on demand) Motor of the sharpening wheel 550 W Sharpening wheel: model x20 mm Blade width from 20 mm to 50 mm Blade thickness from 0,6 mm to 1,1 mm Sharpening time 15 min(4030 mm/ ~4 m) Weight 48,5 kg 13

16 GМ-3 SHARPENING MACHINE FOR BLADES GM-3 sharpening machine is used for automatic sharpening of band saw blades from 20 mm to 50 mm width and from 0,6 mm to 1 mm thickness. Is used for small and medium sawmills. Specifications Voltage Motor of the sharpening wheel Sharpening wheel: model 150 Blade width Blade thickness Sharpening time Weight Value 380 V (220 V on demand) 550 W 150x32х6 mm from 20 mm to 50 mm from 0,6 mm to 1,1 mm 30 min (with 4 m, pitch 22,2 mm) 25 kg 14

17 DWS-2 TOOTH SETTER FOR BLADES It is used to set tooth of band saw blades. The main advantage is accuracy of setting. The best result is provided by features of construction, because it has stable stand and strong guides, that makes good fixing of saw in the process of tooth setting. The rotating handgrip is functioning as leverage, that is convenient and simple at work for an operator. Its construction gives an opportunity to manage rotation angle, that provides to see the instrumental data all the time. Specifications Blade width Blade thickness Value from 20 mm to 60 mm from 0,6 mm to 1,5 mm 15

18 DWS-3 TOOTH SETTER FOR BLADES The device is used for tooth setting of band saw blades and control of its value mm width and 0,6-1,5 mm thickness. The main advantage is that tooth setting is for three teeth and 2 indicators, that show its value. It has stable stand and strong guides, that makes good fixing of saw in the process of tooth setting. Its construction gives an opportunity to manage rotation angle, that provides to see the instrumental data all the time. Specifications Blade width Blade thickness Value from 20 mm to 60 mm from 0,6 mm to 1,5 mm 16

19 HBS-1 SAWMILL HORIZONTAL DEVICE Specifications 17 It is designed for longitudinal sawing of roundwood on industrial wood and unedged sawn timber. The simplicity of design, small dimensions, low power consumption allow the device to be used in subsidiary farms, carpentry shops or directly on construction sites to saw round logs with a diameter of up to 560 mm, while consuming 4 kw / hour of electricity. Value Max width of sawing 560 mm Max thickness of a board 250 mm Min thickness of a board 3 mm Cutting feed speed 2 20 m/min Accuracy of sawing 1 mm/m Driving power of a saw 5,5 kw Board length 0,9 5,2 m Band saw blade: length 3450 mm width mm thickness 0,8 1 mm Weight 365 kg

20 HBS-2 / HBS-4 SAWMILL HORIZONTAL DEVICE It is designed for longitudinal sawing of roundwood 870 mm diameter. Depending on the hardness of wood and its type it is possible to receive 1 sq.m. per hour. Depending on modification there are engines of 7,5 kw or 11 kw power In addition it is possible to establish an automatic cutting feed of sawcarriage and electronic ruler. Specifications HBS-2 HBS-4 Max width of sawing 870 mm 870 mm Max thickness of a board 250 mm 250 mm Min thickness of a board 10 mm 10 mm Cutting feed speed 2-20 m/min 2-20 m/min Accuracy of sawing 1 mm/m 1 mm/m Driving power of a saw 7,5(11) kw 7,5 kw Thickness of sawing 2 3 mm 2-3 mm Cutting speed 25 m/sec 25 m/sec Weight 700 kg 600 kg 18

21 LTM-1 / LTM-2 CROSS-CUTTING MACHINE It is used for cutting the corner or sawing the untrimmed board to sawnwood (beam, edged board). In addition it is possible to establish an automatic cutting feed of sawcarriage and electronic ruler. Specifications Width of sawing board up to 700 mm up to 700 mm Width of trimmed board up to 240 mm up to 240 mm Thickness of sawing mm mm Length of sawing board on demand on demand Saw diameter 350 mm 350 mm Rim diameter of a saw 32 / 50 mm 32 / 50 mm Rotation frequency of a saw 2880 rpm 2880 rpm Cutting feed speed 5,5 kw 5,5 kw Accuracy of sawing 1 mm / 3000 mm 1 mm / 3000 mm Weight 300 kg 300 kg 19

22 MSM-1 EDGE-TRIMMING MACHINE It is used for cross and edge cutting of boards and planks and undercutting of defects. It is advisable to use at furniture and workshops of any difficulty. MSM- 1 is with a saw on a carriage. Specifications 20 Value Max board thickness 85 mm Max board cutting - Length of cutting (width of a board) 450 mm (300 mm) Rotation frequency of a saw 2880 rpm Power 3 kw Diameter of a saw 400 mm Rim diameter of a saw 32 or 50 mm Cutting feed speed manual Weight 70 kg

23 ASSEMBLED ROLLERS FOR RIBBON SUPPORTING For using at different sawmills. It is possible to produce on Your sample on demand. Standard types of issued rollers: 201,202,203,204. The advantage of our rollers is a high quality of producing. They are heat treated and are produced with bearings of the best world s manufacturers that increase their service life. INDICATORS AND MANOMETERS For the measurement over, absolute and differential pressure. Standard types: vibration-proof types of manometers, corresponds to EN standard, dust and liquid protecting level IP65 The manometers and indicators help to control vitally important instrumental data, that increases its durability and service life. Glycerine manometer at a sawmill helps to avoid defects wavy sawing. 21

24 BEARINGS For the transfer of torque. Standard types: Ball, Roller; Radial. Radial thrust, thrust-radial. Thrust. Lineal. BELTS For the transfer of torque. Standard types: Triangular; Toothed; Flat. Driving belt is a main part of the machines and mechanisms, that helps to transfer of torque. The quality of our belts provides faster, more silent and straight work or a tool that increases the productivity and durability of the equipment. 22

25 LUBRICATING FLUIDS (LCF) FOR METAL AND WOOD PROCESSING Our company in cooperation with leading experts of petrochemical industry created new essence LCF (lubricating fluid). LCF is used for withdrawing of warmth out of the cutting tool. It lowers the temperature that increases the stability of a cutting tool, quality of a processed surface and protects the cutting tool and the blank from corrosion. Rational use of LCF provides in certain cases the stability of a cutting tool from 1,5 to 4 times. The advantages of using LCF: Absence of nitrites, chlorides, amines and boric acid, polycyclic aromatic compounds. At mixture with water it forms stable white opaque emulsion. Emulsion is resistant to bacterial activity, stable, with its use there is no unpleasant odour. Emulsion saves good anti-corrosion properties during long period of time and provides permanent protection of equipment. While working does not form a foam or foaming is small. Good lubricating properties provide viable work of a tool and equipment 23

26 24

27 RECOMMENDATIONS ON THE USE AND TECHNICAL SERVICING OF LENKER SAWS Basic terms: Tooth pitch is a distance between 2 top spots of the nearby teeth. This option is always the same. Height of tooth is a distance between the lowest spot самой нижней точки пазуха (впадины) до самой верхней точки зуба. Gullet depth is a distance between teeth, that take out" chip at sawing. Hook angle (top clearance angle) angle of inclination of front tooth edge concerning 90 ordinate. Tooth set is a distance of a tooth bending outwards of a blade. Lenker saw profile A tooth pitch (tooth spacing); B radius in the basis of tooth; C height of tooth; D hook angle (top clearance angle); E - back angle of tooth; F width of a saw; G thickness of a saw; H tooth set; I - cutting edge angle. The preparation of a saw before work is performed according to the type of sawing wood. Hook angle, tooth set, sharpening and right height of tooth are 4 the most important elements of a saw, that determine its ability to cut. The right establishing of a blade on pulleys. The distance between depth to edge of a pulley should be strictly determined. It depends on the type of a bench. You should control the condition of belts on pulleys. If a saw is 0,8 mm far from the wheel, it should be replaced. It is very important to use the belt of a right thickness. Because saws are on the belts with a great pressure. Any thickening on a belt increases the pressure to a blade that causes a vibrating of a bench and reduces service life of a saw. Sometimes under a belt there is a chip. That causes to the same consequences as thickening on a belt. Saw should be supported on both sides of a cutting log as closer as possible to it. The right position of the guiding rollers of a saw provides additional resistance of it at cutting. As a result You saw more quickly, service life increases and the quantity of sq.m. sawed by one saw is higher. How to do this? Make a turn of rollers towards going of a saw at 30 o, establish a 3 mm spacing between the side of roller and the backside of a saw, put down the rollers (pressing on a saw) for 7 mm, make regulation at vertical plane. Saw tension should be about atm. 25

28 Efficient preparation of band saw blades before work is a way to receive quality lumber as a result. Right sharpening and tooth setting of a saw regulated on a sawmill cuts with less effort, high speed, more straight and soft, complying with required geometrical dimentions of a board. In addition the right preparation of a saw for work increases its service life, that reduces expenses on buying new saws. The service life of a saw certainly is one of the options, that is of great interest of owners of sawmills. Surely, everyone aim at receiving as more as possible of sqm of cutting material of every saw. But it isn t easy, because the work of a saw depends on many factors: type of sawing wood, level of pollution of bark of logs, thickness and profile of a saw, is there a mandatory saw washing and debarker, type of guiding rollers of a saw. But the most important are right sharpening and tooth setting! Tooth setting is a distance of a tooth bending outwards of a blade. Tooth set is a main factor of a saw working. As more is a tooth set as wide is a sawing and as more the engine power in needed. The aim of it is making a spacing for a saw at cutting. In other words, it is needed to reduce rubbing between wood and saw in a way, that saw would cut without heating. The value of tooth set depends on the type of wood. As soft and fibrous is a wood as more is a tooth set to reduce the rubbing of fibers. Soft types of wood have hard, long fibers, but hard types don t have. The last is a frozen soft wood type, that cut with a little tooth set. How to know the tooth set of a saw is right? Tooth setting is optimal when a distance between saw blade and wood, that is cutting, has a blend of 65-70% of chip and 30-35% of air. External display of a right tooth set is emission 80-85% of chip. In those cases when a saw is to much tooth setting, the chip is not enough. If a tooth set is not enough, the surface of a board remains tightly pressed, warm chip. Actually chip should be warm to the touch, but now hot or cold. If a saw has to much tooth setting, probably, it would cut bounds, and not enough in waves. If logs of 30 cm diameter are cut at good speed and chip is little warm, You shouldn t try to cut the logs of 60 cm diameter by the same tooth setting, because it is needed to remove 2 times more of chip. So, it is needed to increase the tooth set for 20%. Therefore: logs should be sorted by thickness, before their cutting. There is one important moment: the only the top part of tooth should has a tooth setting, not a whole tooth. The only sharp corner at the top of tooth should be at the process of cutting. Don t forget about indicator of tooth setter is a precision device. It is simple to knock it down. It works in a very stressful conditions. So an indicator wears out over time and is needed to be checked regularly. 26

29 A point of tooth setting of a saw While tooth setting it is important to pay special attention to position of a saw at tooth setter. The fold line should be at the lowest point of gullet or higher. The point of fold (where pusher of tooth setter press on tooth) should be approximately on a half of its height. If a fold line is too low, the ribbon would bend, not a tooth. So the saw will tear before its time. If a fold line is too high, the top of tooth would bend, saw would be unsustainable and cutting would be wave. That reduces the speed of cutting and it is possible a saw breakdown before its time. Incorrect sharpening and tooth setting is a main reason of its breakdown before its time. The whole process of sharpening and tooth setting increases its service life. Problems of the saw tooth setting Tooth set is made only after saw sharpening and edge cleaning from burrs. Here is a number of the main details you should paying attention. At first it is installation and verification of an indicator. Verification isn t a problem. But users often forget about setting a tip of indicator, that should be right at all width of it with regard to measuring plate supplied with a device for tooth setting. Second of all is setting a height of mast and determining the point of tooth inflection. The right position of mast is as following: it should be on the top 1/3 of tooth height. If a position of mast is already correct, You should pay attention to the right setting of limiters. They should be set in a way to flex every teeth in the same point. It is a very important operation, because its influences on sawing accuracy. In third, the setting flange of device. In this case it is 2 moments important. This is the distance of ribbon pitch and edge of flange, that should be the same all time and provide flexion of tooth not a ribbon turn (this is a very common mistake). And it is a condition of guiding bolt of a pressing plate. Band saw blades SHARPENING While cutting by blunt saw the tension of it goes down, because of its heating. Some sawyers fight to this by increasing the tension over recommended. As a result: quick wearing of bearings, pulleys, rollers, belts. But the most important quickly are formed microfractures at saw blade, that run wild and cause its breaking up. Saws become blunt at cutting dirty logs sometimes it is enough to cut only cm. To solve this problem use debarker and clean logs manual. It is forbidden to increase the recommended volume of roundwood or sawing time before sharpening. Actually up to 90% reasons of saw untimely breaking out is incorrect sharpening. Few words about sharpener. Applicants to this position should be selected with max thoroughness. The worker should be assiduous and conscientious, who has completed the training, meticulously perform all articles of sharpening regulations. If you have a such person you don t know what is untimely breakdown of saws. If you don t have such one, we recommend to buy a sharpener with diamond wheel that reduces dependence on human factor. 27

30 Band saw blades sharpening rules First, that is needed to check is configuration correctness of sharpening machine (the position of sharpening wheel concerning a saw). It is necessary to check squareness of plane of sharpening wheel to a saw. Sharpening of the saw is needed not only to sharp the cutting edge, but to take off numerous microfractures that are in gullets of teeth. Most often they appear in a place, that is equidistant to teeth ends. It is the most narrow part of a saw. While sharpening it is important to take off a such quantity of metal from gullets of teeth that will take off microfractures. Also metal should be took off equally to the whole tooth profile. Failure to do so causes besides increasing of a breakdown risk also changing of options of a saw (saw profile and tooth height). In the case, when a saw cut longer, than it was recommended buy a plantmanufacturer, the quantity of metal took off at 1 sharpening should be increased. In the performance of this it is important to check pressing of sharpening wheel to a saw, it shouldn t be overweight. Otherwise saw blade is annealing, reducing its strength. It is mandatory to use LCF while sharpening. Sometimes, even if a small quantity take off can appear an annealing. In this case You should clean the working surface off metal pieces covering it while sharpening by grinding wheel. You should repeat this after 1 circle of saw sharpening. After sharpening check the result using a new saw. If a saw is sharpened correctly its profile and tooth height are constant, in its gullets and on its top the rude risks of abrasive parts of the sharpening wheel are absent (these risks are removed after the main sharpening by grinding), there are no prints of metal annealing, totally took off burrs, cutting edges have correct shape and are enough sharpened. The shape of tooth was developed and checked for years. So it is a mistake to think that saw will cut with any shape of its teeth. The right use of band saw blade can be used until after sharpening its width will be 65% of original. Sometimes there are recommendations not to take off burrs after sharpening. It is a mistake. Because they provoke appearing of microfractures at a saw blade. How to set a saw correctly? It is important to set a saw blade on pulleys: a distance between gullet of tooth to edge of pulley should be strictly constant. If a saw is 0,8 mm far from the wheel, it should be replaced. It is very important to use the belt of a right thickness. Because saws are on the belts with a great pressure. Any thickening on a belt increases the pressure to a blade that causes a vibrating of a bench and reduces service life of a saw. Sometimes under a belt there is a chip. That causes to the same consequences asthickening ona belt. 28

31 The right position of the guiding rollers of a saw provides additional resistance of it at cutting. As a result You saw more quickly, service life increases and the quantity of sq.m. sawed by one saw is higher. How to do this? Make a turn of rollers towards going of a saw at 30 o, establish a 3 mm spacing between the side of roller and the backside of a saw, put down the rollers (pressing on a saw) for 7 mm, make regulation at vertical plane. Saw tension should be about atm according the recommendation of a plant-manufacturer. Cleaning and checking of saws After work a saw should be cleaned off chip and resin, and before sharpening carefully checked. Otherwise the pollution of sharpening wheels is possible, that causes incorrect sharpening for example gullet strengthening after the sharpening and following cracks. Sawing process At cutting saw is warming, that causes its length. When cool off it squeezes to its original size and then excessive tension appears. An sawyer-operator skills play a key role to receive max productivity and durability of a saw, as he control many factors influence to sawing. The sawing speed depends on the type of wood: soft types (conifers in the main) have uneven density of annual circles. Branches require attentive sawing speed regulation. Hard types (except low quality logs) usually can be cut rapidly at stable speed because of their equal density. In general all types differ on density (hardness). As usual the most difficult moment at sawing is when the log is partly frozen. The logs of 20 cm and 80 cm diameter can t be cut at the same result and speed. In the second case the area of sawing increases in nearly 3 times and the volume of chip took off increases accordingly in 3 times. As far as logs dry out they become harder. Some types while dry out cut as hardwood. While sawing dirty logs there is a need to sharp a saw too often. Correct sharpening provides reducing of its width. As thin is a saw as low is a cutting speed, because it is less sustainable to cut. Right position of rollers of a saw helps operator to cut with the highest speed. Sawing should be as quick as it is possible to receive accuracy straight cut and quality material. Cracks in the gullets are one of the factors that limits the band saw blades service life. The most of cracks of saws can be explained by the tiredness of metal, caused by local changes in geometry shape or volume, or manufacturing defect at welding (cracks at weld), or mistakes of sharpening and tooth setting. Cracks at gullets can appear if the steel is low quality. The speed of sawing is determined by diameter and speed of pulley rotation. Normal lineal speed is about 30 m/s. while increasing the lineal speed and the giving speed it is possible to receive cleaner cut, but the service life is reducing because of metal tiredness. 29

32 Sawing in winter Winter is a period for preparation and sawing wood. Because of cold there s no risk of wood lividity. But there are some difficult with machines in the freezing cold. While sawing the frozen wood it is mandatory to pay attention on tooth set. As soft is wood as more is tooth set, hook angle and tooth height. And the opposite: as hard is the type as low is tooth set, hook angle and tooth height. As stated earlier the frozen softwood cut as hardwood. Usually it is the hardest to cut a partly frozen log. In this case the giving speed should be reduced fluently. Tooth setting for it should be as for hardwood. While sawing a wood at lower 0 С temperature use unfrozen liquid with water for washing over a saw. Sometimes they add some liquid for washing dishes. Do not use diesel: it corrodes pulley belts. Service life of a saw Cracks in the gullets are one of the factors that limits the band saw blades service life. The most of cracks of saws can be explained by the tiredness of metal, caused by local changes in geometry shape or volume, or manufacturing defect at welding (cracks at weld), or mistakes of sharpening and tooth setting. Cracks at gullets can appear if the steel is low quality. Stages of preparation band saw blade Stage 1: Preliminary washing of a saw While sawing at high speed the sap stick on a saw. This can influence the quality of the next sharpening. Stage 2: First saw sharpening First sharpening restores squareness of tooth cutting edges against saw body. Stage 3: Second saw sharpening In this case the cutting edge is grinding to the needed sharp. Stage 4: Saw tooth setting Band saw blades are tooth setting in the following way: first tooth to the left, second to the right, third in the centre and so on. 30

33 MISTAKES IN PREPARING OF BAND SAW BLADES Saw blade cracks. Appearing those cracks is connected with incorrect setting of guiding rollers, excessive tension and mistakes of bench operators. Burned gullets of saw tooth. In this case the ribbon blunt to rapidly. It is because the sharpening wheel efforts excessive while sharpening. Incorrect shape of a tooth gullet and inclination angle. Visually is noticeable that the circle passes incomplete tooth profile while sharpening. The mistake set of incline angle of sharpening machine or profile of sharpening wheel, if it is used not CBN. Besides the demolition of sharpening machine eccentric can be a reason of it. Unprocessed part is a place where cracks appear. 31

34 METHODS FOR DEALING WITH PROBLEMS Problem: Cracks of the saw cutting surface Reasons and solutions Overheating of a saw (work without breaks) use saws according to the manufacturer recommendations Incorrect tooth set make a tooth setting according to the type of sawing wood Blunt cutting surface sharp a saw Too high sawing speed low the sawing speed Too low radius of the cutting surface - sharp the saw, increasing radius Too strong or too weak tension of a saw make a tension according to the instruction After finishing work the saw is still tensioned reduce the tension of a saw After sharpening the cutting surface is burned abrasive tool is chosen incorrect is too hard or operator made a mistake Diameter of pulleys is too small use a more narrow saw Saw connected the wood before the needed speed start sawing after seeking the needed speed of rotation on pulleys Incorrect front angle of sharpening for the type of wood sharp a saw again The guiding rollers are too far of a sawing surface set rollers max close to the sawing material Reasons and solutions Problem: Saw backside cracks Too strong or too weak tension of a saw make a tension according to the instruction Too high sawing speed low the sawing speed Bad condition of guiding rollers of a saw, or rollers set in different plane replace rollers or regulate their position Width of guiding rollers is not according its width choose rollers of needed width Saw overheating (work without breaks) use saws according the manufacturer recommendations Guiding rollers vibrating replace rollers of bearings there. Problem: Incorrect geometry of cutting wave Reasons and solutions Asymmetrical tooth setting; too low tooth setting make a tooth set After sharpening there are still burrs take off burrs Low speed of cutting check tension of belts, low the speed of giving head Guiding rollers are worn replace rollers or bearings there; regulate the saw tension Incorrect cooling (saw overheating) regulate the lubricating fluid on a saw Bad fixing of a log check log clamps 32

35