FEATURE ON SAWING

Better productivity and safety with automation

In the steel construction realm, efficiency and automation stand as cornerstones for achieving top-tier quality standards promptly and reliably. Ficep, a global specialist in automated steel processing, meets these imperatives through its integrated solution featuring the Valiant drilling unit and the Katana bandsaw.

The Valiant + Katana system shines particularly bright in its swift process execution, empowered by automation and technology. This amalgamated approach reduces total processing time, outperforming scenarios reliant on specialist labour for finishing stages.

The process maintains a high level of control and predictability, aiding in streamlined production planning. With Valiant, processes such as drilling, automatic marking and milling operations come into play, leaving only welding ahead of the final painting phase. On the cutting front, Katana enables operators to execute both straight and mitred cuts up to 60° quickly.

These saws boast construction features tailored for high-speed performance, while upholding stringent cutting quality standards. Horizontal and vertical hydraulic clamps maximise workpiece stability, while robust motor power and bandsaw blade rotation speeds ensure efficient operations. Automated handling phases further enhance productivity.

The production momentum of this integrated system hinges on Ficep’s direct-drive spindles, channelling 100% of the motor power to the tool.

Notably, the integrated system’s installation stands out for its simplicity, requiring no expensive civil works. This translates to significant time and cost savings for customers, enabling quick production commencement and minimising downtime.

The Valiant + Katana system’s most significant advantage lies in its potential for full automation. With remote control via a mobile app, operators can monitor and manage the system from anywhere, optimising production efficiency even beyond regular working hours and during downtimes.

More information www.ficepgroup.com

Understanding bandsaw down-feed systems

When delving into the world of bandsaw machinery, a fundamental aspect to grasp is the relationship between the saw bow’s descent speed, the applied pressure and the resistance offered by the workpiece. This understanding is crucial for optimal operation and precise cutting, as a guide produced by Saws UK sets out.

Investing in a high-end bandsaw brings notable advantages, especially with sophisticated down-feed systems designed to fully harness the capabilities of the latest bi-metal and carbide-tipped blades. These enhancements substantially boost productivity. 

Down-feed regulation systems in bandsaws vary significantly. Some are straightforward, featuring an adjustable hydraulic valve in the guide system that responds to material resistance. More advanced systems include load detection on the blade drive motor, integrating an interface with a proportional down-feed valve in the hydraulics. Additionally, some machines employ a ball screw system connected to the interface for down-feed control. 

A pivotal feature in some bandsaws is blade deflection detection. This technology automatically slows the down feed to prevent crooked cuts when the blade begins to dull towards the end of its lifespan. 

Modern control systems often include a material directory, enabling operators to set reasonable down-feed rates based on workpiece size. However, this requires accurate data input and may not account for the annealed state of the material, where load detection systems can provide additional guidance during challenging cuts. 

The question arises: can a company justify spending up to £100,000 more for a bandsaw that fundamentally performs the same task? The answer lies in evaluating several factors, including expected service life, precision of cut, ease of use and speed of cut. Saws UK can provide advice in line with customer-specific applications.

More information www.sawsuk.com

How to maximise efficiency with cold saws

Cold saws are essential tools for numerous businesses needing clean, burr-free cuts on various metals. They also find widespread use in general fabrication and machine shops, as well as in structural steel fabrication, HVAC, automotive repair and shipbuilding. Cold saws offer a dependable and efficient method for cutting different solid and hollow metal sections. Dimakin offers a guide (tips and tricks) for improving the performance of cold saws.

It is important to consider the blade tooth count relative to the workpiece material. For example, if using too fine a blade for soft materials, the blade’s gullets will quickly clog, eliminating the machine’s ability to cut effectively.

For those likely to cut multiple materials or profiles over the machine’s lifetime, it might be worth considering a cold saw with the ability to vary speeds. Cold saws such as the CS-350-DM are ideal with their speed inverter dial, allowing infinite adjustment between 24 and 120 rpm. Another tip is to use the coolant system during operation. Coolant lubricates the blade, reduces heat build-up, improves cut quality and extends blade life.

A further important factor in cutting is clamping. Without securing material tightly, no blade will ever be able to achieve a good quality cut. Regular blade sharpening is a further contributor to optimal cutting performance. Dimakin not only offers brand new blades, but a blade resharpening service tool. Last but not least, it is important to maintain a clean a clean work area in and around the cold saw for cut quality. Regularly remove metal chips and debris to prevent them from hindering the cutting process or damaging the saw.

Dimakin offers a comprehensive line of cold saws, from basic single-speed models to feature-packed inverter-driven options with variable speeds.

More information www.dimakin.co.uk

A meeting of visions at BIEMH exhibition

The BIEMH machine tool exhibition in Bilbao, Spain, is always a special occasion to meet old friends and discover new talent. This year, MEP Saws of Italy was particularly excited to meet once more with Juanjo Fernández, known in the art world as ‘The Steel Studio’.


The Steel Studio is not only a producer of metal objects, it is an artist who transforms iron into real works of art. With his creations, Fernández has enchanted judges of international competitions and art lovers from all over the world. His works tell stories of strength and beauty, forging metal into shapes that evoke deep emotions.


At the heart of his creations is an MEP saw, an old but reliable manual Shark 280. According to MEP, these machines are not only industrial machinery, but real ‘magic wands’ that allow artists to transform raw metal into refined art.

“Each cut is a step towards the materialisation of my artistic vision,” says Fernández. “MEP saws give me the precision and creative freedom I need to bring my work to life.”
 

Recently, The Steel Studio decided to buy a second MEP band saw, this time a semi-automatic Shark 332-1 sxi evo, once again demonstrating confidence in the quality and reliability of MEP products.

The Steel Studio uses MEP saws to push the boundaries of imagination, creating works that are both powerful and delicate. MEP’s collaboration with The Steel Studio shows how technology can be at the service of creativity. The saws not only facilitate the production process but become an integral part of the artistic expression. This union is perfectly visible in the artwork, which capture the eccentric and creative spirit of the artist while posing within his creative space.

More information www.mepsaws.it

New Roentgen FIT and FIT Set bandsaw blades

In a significant leap forward for the metalworking sector, German industrial cutting solutions manufacturer Roentgen has unveiled its latest innovation tailored for sawing nickel-based alloys. The Roentgen Fit Set and Fit bandsaw blade are engineered and manufactured to elevate cutting performance, extend tool life and eliminate the need for traditional run-in procedures. This results in saving valuable time and resources for metal manufacturers and engineers. The blades are available in the UK from KR Saws, joint venture between saw blade manufacturers Kinkelder and Roentgen. 

Nickel-based alloys such as Inconel 718 and 625 are known for their exceptional strength, corrosion resistance and high-temperature properties. These materials demand precision cutting solutions that can withstand the rigors of machining while delivering superior results consistently.

The Roentgen Fit Set and Fit Bandsaw Blade rise to this challenge with a blend of innovative technology and precision engineering. Designed with a keen focus on durability and performance, a key feature of the blades is their long service life. Utilising advanced materials and advanced manufacturing techniques, KR Saws says that the new Roentgen blades offer exceptional longevity, significantly reducing the frequency of blade changes and associated downtime.

Traditionally, new cutting blades require a run-in period to optimise performance. However, the Roentgen Fit Set and Fit bandsaw blades are engineered to deliver peak performance right out of the box, eliminating the need for time-consuming run-in procedures.

With a focus on precision and efficiency, the blades deliver clean, accurate cuts with minimal heat generation, resulting in improved surface finish and reduced material waste.

Energy savings are a further benefit. With the ability to reduce cut times, these proprietary bandsaw blades can reduce cut times and invariably reduce energy consumption for end users.

More information www.krsaws.co.uk