Sintered tools have a reputation in metal processing for being particularly hard-wearing and for maintaining their sharpness over a long period. However, processing saw blades, drills and milling tools proves to be time consuming as a result of their particular hardness. This is why the saw blade professionals from Alesa in Switzerland started their own development process to design a grinding machine for circular saw blades. The fully automated Denta Combi 160 is designed for multi-shift operations. Here, precision synchronous servomotors featuring a wash-down coating from Kollmorgen are responsible for positioning the high-frequency grinding heads accurately.

Grinding hard materials involves the major challenge of dissipating the generated heat through water or oil as effectively as possible. The saw blades are so sensitive that temperatures at the edges of more than between 180 and 200°C can result in immediate changes in material performance. The structure deteriorates and hardness reduces considerably.
With this in mind, a high-pressure oil jet is deployed by the Denta Combi so that teeth remain as cool as possible during chamfering. However, as water is more effective than oil in absorbing friction heat during grinding, the machine engineer has to increase the oil supply pressure – and integrate a CO2 extinguisher into the system. In order to prevent the positioning drives inside the processing centre from adverse damage through contact with the cooling liquid, the machine builder uses specially coated synchronous servomotors from Kollmorgen – the AKM Washdown range with a coating made from a two-component epoxy resin. This protects the units securely from the impact of corrosive chemicals. The extremely smooth surface also ensures that liquids are able to run off without residue.
For further information www.kollmorgen.com

At the METAV 2018 exhibition in Germany last month, a forum on sawing technology was held for the first time at the show. The forum showcased the latest developments and solutions, ranging from simple single-blank cutting in a workshop environment all the way through to mass production.

The VDW (German Machine Tool Builders’ Association), in conjunction with the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA), organised the symposium. “We are purposefully aiming at fostering a dialogue between machinery and tool manufacturers, and end users,” emphasises Tim Mayer, group leader sawing technology at the IPA.
In three thematic blocks of sawing machines, sawing tools and process optimisation, the IPA and various market leaders from the sawing sector presented application-relevant, solution-led approaches. Participants were thus able to acquire an overview of current trends, not only in sawing processes, but in the tools used and the manufacturing and automation processes involved. This enabled them to form a picture of the present status in terms of ongoing research, while at the same time finding out from technology leaders what is already possible in entrepreneurial practice.
In times of digitalisation and networking, the subject of Industry 4.0 must never be ignored, of course. The forum accordingly addressed the opportunities and options for sawing machines and the networking of downstream processes.
For further information www.metav.com

With the latest automatic machine from its HBE series, Behringer says it has come up with a way of combining the benefits of high-performance machines for one-off sawing tasks, with the solid, tried and tested characteristics of a classic mitre saw. High cutting outputs, simple handling and precise angular cuts are said to be among the key attributes of the new Behringer HBE320-523GA mitre-cutting bandsaw.

With a cutting range on flat materials of 520 x 320 mm, and bilateral mitre cuts of 45° (and up to 30° on the left), the saw has many features in common with the HBE Dynamic series. The guidance system in its torsionally rigid gantry design and bilateral band wheel bearings are intended to ensure quiet running and precise cuts. The band-guiding components are made of vibration-damping grey cast iron, which has a positive impact on the quality of the cut surface, and makes for longer blade life, says the company. Electrically powered chip brushes clean the saw blade of adhering chips synchronously with the saw drive system.
The inclined position of the band wheels helps prolong the life of bandsaw blades by reducing fatigue due to cyclical bending. A fully automatic height adjustment facility for the saw frame, and lowering of the saw when in rapid traverse, help cut non-productive time to a minimum.
The inclined position of the bandsaw blade allows components such as girders, angled steel and U-profiles, as well as hollow rectangular profiles, to be sawn at higher speed and with less burr.
For further information www.behringer.net

Sawing tough, highly tempered steel bar for a medical engineering application presented a challenge to Bavarian tool and workshop equipment manufacturer, Werner Weitner, as cutting times were long. However, the installation of a KastoWin Pro AC 5.6 bandsaw has made production more efficient by halving processing times.
Department manager Florian Winhard says: “We had to process a highly tempered V2A [304 stainless] steel over a large range of diameters for a medical engineering customer. Our existing saws could only use bimetal blades, so cutting times were up to 15 minutes, which we felt was unsatisfactory.

“As a result, we sent a material sample to Kasto ready for trials on different saws,” he continues. “The results obtained on the KastoWin Pro AC 5.6 automatic bandsaw using a carbide blade were impressive. Cycle times of 7-8 minutes were achieved, around half the time needed by our other saws.
“A major advantage is that we can switch between carbide blades and less expensive HSS bi-metal blades at any time. So we can cut not only difficult-to-machine materials, but standard steels, economically.”
The KastoWin pro AC 5.6 is designed for a variety of applications in steel stockholding, steel production, forging mills, machine manufacturing and the automotive industry. A notable feature is the frequency-controlled, 11 kW drive motor, which allows carbide as well as bimetal blades to be used. Users can therefore be flexible in their choice of tool, reducing costs and optimising cutting speed and efficiency.
The working range of the KastoWin Pro is 560 mm and the smallest dimension that can be cut is 25 x 25 mm.
For further information www.kasto.com