SUBCOURSE OD1646

EDITION 8

BANDSAW OPERATIONS

USARMYREPAIRSHOPTECHNICIANWARRANT OFFICERADVANCEDCORRESPONDENCECOURSE MOS/SKILLLEVEL:441A BANDSAWOPERATIONS SUBCOURSENO.OD1646 USArmyCorrespondence CourseProgram 7CreditHours GENERAL Thepurposeofthissubcourseistointroducetheuseofthebandsawmachine and to describe the methods used in maintaining and troubleshooting this machineforpossibleproblemsormalfunctions. The scope of this subcourse covers a description of types of bandsaw machines used in the U.S. Army. The general methods for using these machinesarealsodiscussed.Includedinthesubcourseareinstructionsfor maintainingandtroubleshootingthebandsaw. Sevencredithoursareawardedforsuccessfulcompletionofthissubcourse. Itconsistsoftwolessonsdividedintotasksasfollows: Lesson1: USESOFTHEBANDSAW TASK1: Describetheuseofthebandsawmachine. Lesson2: BANDSAWMAINTENANCEANDTROUBLESHOOTING TASK1: Describethemethodsusedtorepairandadjustthebandsaw. TASK2: Describetheproceduresfortroubleshootingthebandsaw.

BANDSAW OPERATIONS - OD1646 TABLEOFCONTENTS Section TITLE ................................................................. TABLEOFCONTENTS..................................................... Lesson1: USESOFTHEBANDSAW...................................... Page i ii 1 1 50 52 53 53 65 85 87 89

Task1:Describetheuseofthe bandsawmachine.................................................. PracticalExercise1............................................. AnswerstoPracticalExercise1.................................. Lesson2: BANDSAWMAINTENANCEAND TROUBLESHOOTING..........................................

Task1: Describethemethodsused torepairandadjustthebandsaw................................. Task2: Describetheproceduresfor troubleshootingthebandsaw...................................... PracticalExercise2............................................. AnswerstoPracticalExercise2.................................. REFERENCES............................................................

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Whenusedinthispublicationhe,him,his,andmenrepresentboth themasculineandfemininegenders,unlessotherwisestated.

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BANDSAW OPERATIONS - 0D1646

STUDENTNOTES

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 LESSON1 USESOFTHEBANDSAW TASK1.Describetheuseofthebandsawmachine. CONDITIONS Within a selfstudy environment and given the subcourse text, without assistance. STANDARDS Withinthreehours REFERENCES Nosupplementaryreferencesareneededforthistask. 1. Introduction

Asawingmachineisamachinetooldesignedtocutoffbarstock,tubing, pipe, or any metal stock within its capacity, or to cut sheet stock to desired contours. The sawing machine functions by bringing a saw blade containing cutting teeth in contact with the workpiece to be cut, and drawingthecuttingteeththroughtheworkpiece.Thesawingmachineismuch fasterandeasierthanhandsawing,andisusedprincipallytoproducean accuratesquareormiteredcutonrectangularorcylindricalmaterial. Oneofthetwocommontypesofsawingmachinesusedformetalcuttinginthe machineshopisthebandsawmachine.Thebandsawmachinecutsbydrawinga continuous metalband,calledabandsawblade,acrosstheworkpiece. The bandsawbladeissupportedanddrivenbyadrivewheelandanidlerwheel. This subcourse describes bandsaw operations and maintenance. This lesson introducesthreecommonmodelsofbandsawmachinesanddescribestheiruse. Inlessontwo,themethodsformaintaining,

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 repairing, and troubleshooting these three bandsaw machines will be discussed. 2. TypesofMetalCuttingBandsaws

Metal cutting bandsaw machines fall into two basic categories: horizontal machinesandverticalmachines.Verticalbandsawmachinesaremorecommonly used. Onverticalmachines,theblade'scuttingpositionisverticaland cutsintothesideofthestock.Thebladerotatesonafixedtrackbetween the idler wheel mounted above the worktable and the drive wheel mounted beneath the worktable. The stockismovedagainstthebladetomake the cut.Onthehorizontalbandsawmachine,thecuttingpositionofthebandsaw bladeishorizontalandcutsdownwardintothestock. Thedriveandidler wheelsarepositionedlengthwiseonthesawingmachineframe,whichpivots fromacornerofthesawingmachinebed. Withthehorizontalmachine,the stockisfixedrigidlyinavisetothebedofthemachine,andthebladeis fed downward into the workpiece. The horizontal bandsaw machine is used primarily for cutting stock to length, either at right angles or to any desiredmiterangle.Theverticalmachineismoreversatileandcanbeused for contour cutting, filing, and polishing, as well as for simple stock cutting. a. Vertical Bandsaw. The verticalmetalcuttingbandsawmachine,being themorecommonofthetwotypesofbandsawmachines,isusuallyidentified asa"bandsawmachine"withoutusingtheword"vertical."Atypicalbandsaw machine (figure 1 on the following page) is driven by an electric motor through a belt transmission which permits adjustment of the blade speed through a range of speeds. The table may be tilted fronttoback or sidewaystomakemiteredcuts. Themetalcuttingbandsawmachinedoesnot require preformed bandsaw blades. An electric butt welder and grinding wheel are fastened to the sawing machine. The welder is used to weld a lengthofbladeintoacontinuousband,andthegrindingwheelisusedto remove beads caused by the welding. Since the machine can weld its own blades,internalcuttingispossible.Whenmakinginternalcuts,theblade isinsertedthroughaholecutintheworkpieceandisthenweldedintoa bandandmountedtothemachine. Aftercuttingtheinternalshapeinthe piece,thebandiscutsothatitcanberemoved.

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 Anattachmentforthemetalcuttingbandsawtwiststheblade30or90so thatstockwhichnormallycouldnotbecutbecauseofinsufficientclearance of the sawing machine column can be successfully cut. Other attachments permit the use of band files andpolishingbandsinplaceofthebandsaw blade. Adjustable guides for holding and feeding workpieces are also provided. The machine has a power feed mechanism operated by counterweights. Forcedairforchipremovalissuppliedbyanairpumpin thebaseofthemachine. FIGURE1.THEVERTICALBANDSAWMACHINE.

b. Horizontal Bandsaw. The typical metal cutting horizontal bandsaw machine(figure2onthefollowingpage)isafloormountedmachineusedfor simple cutting of solid steel, tubing, and odd shaped material. The materialtobecutismountedinaviseattachedtothebedofthemachine. An electric motor drives the bandsaw blade through a belt and pulley arrangement from which three speeds may be obtained. The sawing machine frame,upon

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 which thedrivewheel,idlerwheel,bandsawblade,andmotoraremounted, pivots from one corner of the sawing machine bed. The frame is counterbalancedbyatensionspringbetweentheframeandthebed.Feedis controlledbypositioningaslidingweightalongabarfixedtothetopside ofthesawingmachineframe.Adashpotispositionedbetweentheframeand bed to stabilize the feed movement and prevent any quick movement of the framethatcouldcausedamagetothebandsawblade.Theviseusedtohold the material being cut is a quickpositioning type and can be adjusted easily to any angle. An adjustable workpiece stop is provided for rapid positioningofproductionworkpieces. FIGURE2.AHORIZONTALBANDSAWMACHINE.

3.

ModelsofVerticalBandsawMachines

Sincetheverticalbandsawmachineismorecommonthanthehorizontaltype, three models of vertical bandsaw machines will be considered in this subcourse.

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 a. Model 16120. Model 16120 is a floor mounting, metal cutting, verticalbandsawmachine(figure3).Ithasa16inchthroatdepth,andcan accommodateasawbladeorafileband.Theheavy,ribbed,castirontable is24x24inches;itcanbeadjustedforatiltof10totheleftor45 to the right. Precision insert guides are furnished with the machine to coverallsizesofsawbandfrom1/16to3/4inch.Thedrivemotorisa208 volt,60cycle,3phaseelectricmotor.Poweristransmittedfromthedrive motor to a variable speed pulley, and then to the twospeed transmission whichinturndrivesthelower FIGURE3.FEATURESOFMODEL16120.

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 sawbandwheel.Asawbladewelderwithgrinderismountedinthemachine column. b. Model26121M. Themodel26121Misafloormounting,metalcutting, verticalbandsawmachine.Ithasa24inchthroatdepthandcanaccommodate a 1 inch maximum bandsaw blade and a 1/2 inch maximum band file. The worktable(figure4onthefollowingpage)measures26x26inches;itcan bemanuallytitledupto45totherightandupto5totheleft.Power isfedfromthe220volt,60cyclemotorthroughavariablespeedpulleyto the threespeed transmission (figure 5 on page 8). The model 26121M bandsawmachinehasanintegralbuttwelderandgrinder. c. Model 26141. Model 26141 is a floor mounted, metal cutting, vertical bandsaw machine (figure 6 on page 9). It has a 26 inch throat depth.Theheavyduty30x30inchtablehasaremovablecenterdisk.The tablecanbetiltedmanuallytoamaximumof5totheleftand45tothe right. Thefivehorsepowermotordrivesavariablespeedpulleywhich,in turn,drivesthethreespeedtransmission.Thebandsawmachineisequipped withabuttwelderandgrinder. NOTE Intheremainderofthissubcourse,theterm"bandsaw machine" refers only to the vertical metal cutting bandsawmachine. Operationsforthehorizontalmetal cuttingbandsawmachinewillnotbediscussed. 4. UsesofBandsawMachines

Thebandsawmachineisusedforexternalandinternalsawing.Withtheuse of attachments, the bandsaw machine can also serve a variety of other functions. Band files and polishing bands can be used in place of the bandsaw blade for filing and polishing operations. A disk cutting attachment permits the cutting of true circles. An angular blade guide attachmentisfurnishedwithmostbandsawmachines.Thisattachmenttwists thebandsawbladesothatlargeorlongworkpiecesthatwouldnotnormally clearthebandsawmachinecolumncanbecut. Amiterguideattachmentcan beusedtoguidetheworkpieceatanyconvenientangle.

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1

FIGURE4.MODEL26121MFEATURES FRONTVIEW.

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE5.MODEL26121MFEATURES REARVIEW.

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE6.MODEL2614FEATURESANDCONTROLS.

a. General Bandsawing Operations. The bandsaw machine can be used for makingexternalstraightline,curved,orcontouredcuts.Whenpowersawing withthebandsawmachine,properbladeandguideselectionareimportant. (1) Blade Selection. Bandsaw blades are manufactured in two forms. Theyaresuppliedin

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 rolls of 50 to 500 feet for use on machines that have butt welders for forming their own blade bands. Bandsaw blades are also supplied in continuousweldedbandsinstandardsizesformachineshavingnoprovisions forweldingbladebands.Allthreemodelsdiscussedinthissubcoursehave provisionsforweldingbladebands. (a) Characteristics of Blades. Bandsaw blades are made from special alloy steel. The blades are made flexible by annealing the body of the bladeandhardeningonlytheteeth.Metalcuttingbandsawbladeshavetheir teethsettoproduceakerf,orcut,slightlywiderthanthethicknessof thebladetopreventthebladefrombeingpinchedbythestock.Thesetting of the teeth for most bandsaw bladesiscalledtherakersetting. Raker toothbladeshaveonetoothbenttotheright,thenexttoothbenttothe left, and thethird tooth set straight(figure7). Thepitchofbandsaw bladeteethisthenumberofteethperlinearinchoftheblade(figure8on thefollowingpage).Forexample,ifabladehas14teethperinch(tpi), ithasapitchof14,oritmaybereferredtoasa14pitchblade.Metal cuttingbandsawbladesrangefrom6to32teethperinch.Thefinertooth bladesareusedforsawingthinstock;thecoarsetoothbladesareusedfor sawinglargestockandsoftmetal. FIGURE7.RAKERTOOTHSETTING.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE8.PITCHOFTEETH.

(b) SelectingtheProperBlade. Bandsawbladesareselectedaccording tothetypeofmaterialtobecut,thethicknessofthematerialtobecut, andthesawingoperationtobeperformed. 1 BladePitch.Softorgummymaterialsandthickstockrequirecoarse toothbladestoprovideadequatechipclearance. Hardmaterialsgenerally requirefinertoothblades.Finetoothbladesarealsonecessaryifagood finishisdesired.Sincetwoorthreeteethofthebandsawblademustbein contactwiththeworkpieceatalltimestopreventchatterandshearingof teeth,finetoothbladesareusedtocutsheetmetalandtubing.Ifsheet metal is too thin to meet this requirement with the finest tooth blade available,themetalshouldfirstbemountedonplywood,fiber,orthicker metaltostiffenit.Table1,onthefollowingpage,maybeusedasaguide inselectingtheproperpitchbandsawbladefordifferentmetalsandmetal thicknesses.Ifthestockisexceptionallylarge,coarsertoothbladesthan thoserecommendedforsolidstockmaybeused.Remember,twoormoreteeth must contact the workpiece at all times to prevent shearing of the blade teeth. If the recommended pitch for solid stock fails to meet this requirement,abladewithfinerpitchmustbeselected. 2 Blade Width. When straightsawing,thewidestbladeavailableof theproperpitchshouldbeused. Thinnerbladesarerequiredforcontour sawingtopreventthebodyofthebladefromrubbingthesidesofthecut when cutting sharp curves. When curves or radii are to be cut on the bandsawmachine,thewidestbladeadaptabletothesharpestradiustobecut shouldbeused. Narrowbladesaremoreeasilybrokenthanwidebladesand shouldbeusedonlywherenecessary.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 TABLE1.SELECTIONOFBLADEPITCH.

Table2liststhebladesizeswhichcanbeusedforcuttingdifferentsize radii.Ifthepropersizebladefortheradiustobecutisnotavailable, thenextsizenarrowershouldbeused. TABLE2.BANDSAWINGRADIUSGUIDE.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 (c) BladeWear.Bandsawbladesbecomedullfromprolongeduse,butsome conditions promote greater than normal wear on the blades. Blades dull quicklyifusedattoohighaspeedforthematerialbeingcut. Also,if thematerialtobecutistoohardforthepitchoftheblade,abnormalwear willresult.Thiscanbecausedbyhardspotsincastironorweldedmetal, and usually can be anticipated so that the operator can reduce the feed. Rubberandsomefibersorplasticscontainabrasivematerialthatwilldull sawbladesregardlessofthesawingspeedandfeed.Prematurebladedulling oftenoccursfromusingtoofineapitchbladeandfromfeedingtooquickly. (d) Symptoms of Worn Blades. Several symptoms appear when a bandsaw blade is dull. If the bandsaw blade cuts slowly or not at all when the workpieceisfedbyhand,thebladeisprobablydull.Bladeteethwhichare brightonthecuttingedgealsoindicateadullblade. Anothersignofa dullbladeiswhenitbecomesdifficulttofollowalineorwhentheblade forcestoonesideortheother. Adullbladeisalsoindicatedwhenthe chipsfromcuttingmetalsaregranular(exceptforcastironwhichproduces granularchipswithbothsharpanddullblades).Withthemachinestopped, orwiththebandsawbladeremovedfromthemachine,runafingerslowlyover the teeth in the cutting direction. If sharp edges cannot be felt, the bladeisdullandshouldbereplaced. (2) GuideSelection.Standardsawguidesarefurnishedwiththebandsaw machines and are designed to guide the saw blade to a constant location. The standard guides are installed directly on the post and keeper block. Adjustablesawguideinsertsallowtheguidestobeadjustedtothesizeof thesawbladetobeused.Twospecialattachments,theangularbladeguide andthemiterguide,provideaddedcapabilitiestothebandsawmachine. (a) AdjustingSawGuideInserts.Sawguideinsertsareprovidedsothat theguidescanbeadjustedforthesizeofsawbladetobeused.Thesetof insertsmarkedforthewidthofsawbandbeingusedshouldbeselected.The righthandinsert(figure9onthefollowingpage)isplacedinthemilled slotoftheguide,anditsadjustingscrewistightenedlightlysothatthe insertisabletoslideintheslotbutwillstillholdits

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 positionwhenitisreleased.Usingtheproperinsertgagetomatchthesaw bandbeingused,placethegageintheoppositeslotandadjusttheinsert sothatitmeetsthetwogagingedges.Thentightentheinsertsecurelyin place. Place the left hand insert in the slot and tighten the screw lightly. Thenplacethegageedgewisebetweenthetwoinserts. Bringthe lefthandinsertdownsothatitrestsagainstthegage.Whenthegageis removed,thegapleftwillbetheproperthicknessforthesawband. FIGURE9.SAWGUIDEINSERTS.

(b) Angular Blade Guide. The angular blade guide attachment is furnishedwithmostmetalcuttingbandsawmachines.Thisattachmenttwists thebandsawbladesothatlargeorlongworkpiecesthatwouldnotnormally clearthebandsawmachinecolumncanbecut. Thebladeistwisted30on somemachinesand30to90onothers.Theangularbladeguideattachment consistsofanupperbandsawbladeguidethatattachestothesawingmachine postandalowerbandsawbladeguidethatattachestotheframebeneaththe table. Figure10onthefollowingpageshows90sawguidebrackets(with guidesandinsertsinstalledonthebracket)asinstalledonthemodel2612 1Mbandsawmachine.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE10.ANGULARBLADEGUIDEATTACHMENT.

(c) MiterGuide.Themiterguideattachmentisadeviceusedtosupport andguideworkpiecestothebandsawbladesothattheworkpiecemaybecut ataspecificangle.Theattachmentcanbeswiveledandlockedtoguidethe workpiece at any convenient angle. On the three bandsaw machine models discussedinthissubcourse,themiteringattachmentissidemounting.When notinuse,theattachmentisswunguptotherightandaroundontheslide rodsothatithangsbelowthetable.Figure11onthefollowingpageshows atypicalsidemountingmiteringattachment.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE11.THEMITERGUIDE.

(d) RipFence. Theripfenceaccessoryhelpsinmakingeven,straight cuts.Atypicalripfenceisshowninfigure12onthefollowingpage.In makingalongcutwitharipfenceasaguide,checktobesurethatthesaw band used is not worn on one side. This will cause the work to wander relativetotheripfenceguide. (e) DiskCuttingAttachment.Thediskcuttingattachment(figure13on page18)permitscuttingtruecircles,eitherinternallyorexternally,or anydiameterfrom21/2to30inches.Thisattachmentisboltedtothepost withcapscrewsandwashers. (f) ScrewFeedAttachment.Thescrewfeeddevice(figure14onpage18) is a machine tool attachment onsomemakesofbandsawmachines,and is a componentpartofotherbandsawmachines.Thescrewfeedaccessoryisused forprecisioncontoursawingofheavywork.Itisahandoperatedmethodof feedingtheworkpieceintothebandsawbladeorbandfile. Thedeviceis usedwithaworkholdingjawtofeedtheworkpieceintothebladeatangles otherthan90totheblade.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE12.ARIPFENCE.

(3) Band Tensioning. It is essential that the saw band be correctly tensioned in order to obtain a maximum accuracy and cutting rate. Band tension is applied by turning the removable handcrank (tension handle) locatedbelowthesawhead. The band should be tightened to the proper tension indicated on the band tension scale mounted on the machine. The figures on this scale are recommended tensions and are based on the most common gages and pitches used. When using bands with coarser pitch or lighter gage, the tension should be reduced. The tension should be increased when using heavier bands. A new band may stretch slightly as it is being used. It is importanttocheckthetensionofthebandsothatitdoesnotbecometoo slack. Table3onpage19givestherecommendedtensionsforallsizesof bandtools. (4) Tracking the Band. The upper wheel must be adjusted so that the bandtrackscorrectlyonbothwheels. Toaccomplishthis,theupperwheel canbetiltedonitsaxis.Assumingthatthesawbandhas

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE13.DISKCUTTINGATTACHMENT.

FIGURE14.SCREWFEEDDEVICE.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 TABLE3.RECOMMENDEDBANDTENSIONS.

beencorrectlyinstalledandtensioned,thetrackingadjustmentcanbemade byopeningthewheeldoors,pressingthestartbutton,andobservinghowthe band tracks. The tilt controls(figure15onthefollowingpage) can be used to adjust the upper wheel tiltuntilthebandtracksproperly. The bandistrackingproperlywhenthebackedgeofthebandjusttouchesthe sawguidebackupbearings.Thebandshouldridenearthecenteroftheband wheeltire. Whenthebandistrackingcorrectly,thetiltlockshouldbe tightened. CAUTION Do not stand in front of bandsaw when operating machine or rotating upper wheel by hand to track blade. (5) Band Installation. The procedures for installing a band differ slightlyfrommodeltomodel.Theprocedureforinstallingabandonmodel 26141isconsideredtypicalandisdescribedhere.Toinstallaband,the bandwheeldoorsareopened.Thenthebarwhichcrossesthetablesawslot justbelowthefrontedgeofthetableisunlockedandopened.Thesawband guard is then removed from the post. Gloves are used when handling the band,asitiscarefullyplacedoverthewheelsandbetweenthesawguide inserts.Thebandguardisthenreplaced,andthebarisclosedandlocked over the table slot. Finally, the wheel doors must be closed. Blade tensionshouldbesetoradjusted.SeeTM9341922710,page10.

19 BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 (6) Laying Out Workpieces. When laying out workpieces for bandsaw operations, the size of the stock must be considered in relation to the clearance of the bandsaw machine column. For straightline sawing, the clearanceiseasytojudge;however,forcontoursawingoflargesizestock, thedirectionsofcutmustbecarefullyplannedtopreventthestockfrom hittingthecolumn.Ifasmallsectionistobecutfromalargesheetof metal,thesectionshouldberoughlycutoversizefromthesheet,andthen carefullycuttotheexactoutline. FIGURE15.TILTCONTROLS(MODEL26121M).

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1

(a) LayingOutPiecesforCircularSawing.Whenacircleordiskisto be sawed using the disk cutting saw attachment, a compass or pair of dividersshouldbeusedtoscribeacircleofthedesireddiameteronthe stock. Ifpossible,thecircleshouldbescribedbeginningatoneedgeof thestocksothatthebandsawblademaystartthecutwithoutpreliminary sawingornotching.Next,acenterholeshouldbedrilledorcenterpunched intothedisktoacceptthecenterpinofthediskcuttingattachment.The holeshouldbemadeonlyasdeepandaslargeasneededforthecenterpin. Toolargeaholewillcausethecenterpintofitloosely,whichwillresult inaninaccuratecut. (b) LayingOutPiecesforContourSawing.Whenanoutlineistobecut thatconsistsofmorethantwointersectinglines,theexactshaperequired shouldbescribedonthestock.Whenlayingoutthepiece,saveunnecessary cutsbytakingadvantageofstraight,cleanedgesontheuncutstock. The bandsawbladesizeshouldbeselectedaccordingtothesizeneededtocut thesmallestradiuslaidoutontheworkpiece.Thenatwistdrillequalto orgreaterindiameterthanthewidthofthebandsawblademustbeselected. Using this drill, drill a hole in the solid stock in each corner of the pattern (figure 16 on the following page), making sure the holes fall completelywithinthesectionofmaterialthatwillberemoved.Theseholes are needed when sawing to permit the change of direction of the bandsaw bladefromonecuttotheother. Ifaninternalsectionistoberemovedfromthestock,andtheedgemust remainunbroken,layoutanddrillastartinghole,usingadrilllargerin diameter than the width of thebandsawblade. Thebandsawbladewill be insertedthroughthisholebeforebeingweldedintoabandandinstalledon thebandsawmachine. (7) BandsawSpeedsandSpeedControls. Thecuttingspeedofabandsaw machineisthespeedofthebandsawbladeasitpassesthetable,measured infeetperminute(fpm).Properbandsawspeedsareimportantinconserving bandsaw blades. Too great aspeedforthematerialbeingcutwill cause abnormallyrapidbladewear. Tooslowaspeedwillresultininefficient production.Ingeneral,theharderthematerial,theslowerthespeedthat shouldbeselected.Conversely,thesofterthe

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE16.HOLELAYOUTSFORCONTOURSAWING.

material, thefaster the speed thatshouldbeselected. Itisalso true thatthefasterthespeed,thefinerthefinishproducedonthecutsurface. This principle applies to light feeds in conjunction with fast speeds. Table 4 shows the recommended sawing speeds for different materials. In general, the faster speeds should be used to saw thin materials, and the slowerspeedsshouldbeusedforthickmaterials. TABLE4.BANDSAWINGSPEEDS.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 TABLE4.BANDSAWINGSPEEDS (CONTINUED).

Allmetalcuttingbandsawmachineshaveseveralcuttingspeedswhichcanbe selected. Since the diameter of the drive wheel of the bandsaw machine establishes a fixed ratio between the motor or transmission speed in revolutions per minute to the blade speed in feet per minute, it is not necessary to convert revolutions per minute into feet per minute as with mostothermachinetooloperations. Thespeedsareidentifiedinfeetper minuteonthebandsawmachinespeedselectorcontrols.Somemachineshavea speedindicatorwithwhichacarefulcheckofsawingspeedsmaybemadewhen themachineisoperatingwithorwithoutaload. (8) Bandsaw Feeds. The feed of a vertical bandsaw machine is the pressure applied to the bandsaw blade by the material being cut. With verticalbandsawmachines,thefeedisappliedtotheworkpieceinsteadof thesawblade.Theworkpiecemaybehandfedorpowerfed,dependingupon theoperationtobeperformed.Cuttingcurvesorspecialcontoursrequires thattheworkpiecebefedintothebandsawbladebyhand. (a) PowerFeeding. Thepowerfeedonabandsawmachineisoperatedby adjustable weightsinthemachinepedestal. Theweightsareconnectedby cablestooneoftheworkholdingattachmentsofthesawingmachinetopull the workpiece against the bandsaw blade. To operate the power feed, the weightsareraisedbydepressingapedalandthecablesarethenfixedto theworkholdingattachment. Whenthepedalisreleased,theweightspull thepieceintotheblade. (b) General Rules for Feeding Workpieces. A number of general rules applytofeedingworkpiecesonbandsawmachines. Thefeedshouldbelight whenstartingacut.Thepressurecanbeincreased

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 after thecutisestablished. Also,hardmaterialsrequirelighterfeeds thansoftermaterials.Itisgenerallytruethatwiderbandsawbladeswill withstand greater pressures than narrow blades and can therefore be used with heavier feeds. When hard spots in the material being cut are encountered,thefeedshouldbereduceduntilthespotsarecutthrough.A lightfeedshouldbeusedwhencuttingcurves;aheavierfeedcanbeused forstraightlinecutting. (9) Coolants.Mostsawingmachinesusedinmilitaryoperationsaredry cutting machines; that is, they are not intended for use with liquid coolants.Thesebandsawmachinescontainairpumpsandhosesthroughwhich ajetofairisdirectedagainstthebandsawbladeandworkpiece.Theair acts as bothacoolantand asameansofremovingchipsfromthecutting area. Thenozzleoftheairhoseshouldalwaysbedirectedatthecontact areaofthebladeandworkpiece. Themodel26141bandsawmachineusesa mistcoolant,designedtodirectafinemiststreamofliquidcoolantonthe bladeteethandworkpiece. (10) SafetyPrecautions.Whenusingorservicingthebandsawmachine,it isimportanttomakesafetyahabit.Besuretoclosethedoorsandreplace all covers and safety guards before operating the machine. Wear safety glassesandweargloveswhenhandlingthesawband. DONOT,however,wear gloveswhenoperatingthemachine.Setthesawguidesasclosetothework as possible. Close the band wheel cover before tensioning the band or starting the machine. Disconnect the electrical supply before removing panelsordrivecovers.Keephandsawayfromthemovingsawbandorblade. Before working on the machine, always check for these and other safety precautionsinthetechnicalmanual(TM)appropriatetothebandsawmachine beingoperatedorserviced. b. External Sawing. External sawing is the process of using the bandsaw machine to make saw cuts that begin at the outer edge of the workpiece.Thesecutsmaybestraightline,curved,orcontoured. (1) StraightLineSawing.Inatypicalexampleofstraightlinesawing, abandsawbladeofthedesiredpitchforthematerialtobecutis

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 selected.Thebladeshouldbeaswideaspossibleforstraightlinesawing. Then the desired speed is set on the bandsaw machine. The workpiece is positionedatthedesiredangleinoneofthebandsawmachineattachments. Thenthecableisconnectedtothepowerfeedmechanism(ifthepowerfeed is to be used). The bandsaw machine is then started. The workpiece is lightlyfedintothebladetostartthecut.Oncethecuthasbeenstarted, thefeedcanbeincreased.Ifthefeedisbeingdonebyhand,thepressure applied to the workpiece by the operator can be varied to find the best cuttingconditions. Straightlinesawingisperformedonthebandsawmachinebyusingoneora combination of several mechanisms or attachments: the miter guide attachment, with or without a power feed; the screw feed device, with or withouttheworkholdingjawdevice;andtheworkholdingjawdevicewith powerfeedandtheangularbladeguideattachment. (a) The Miter Guide Attachment. The miter guide attachment on some machinescanbeconnectedtothepowerfeedmechanism. Onothermachines, feedingmustbedonebyhandwhenusingthemiterguide.Theworkpieceis clampedorhandheldagainstthemiterguideattachment,andtheworkpiece and attachment are moved against the bandsaw blade. The miter guide assembly moves on a track parallel to the blade, thereby assuring a straightlinecut. (b) TheScrewFeedDevice. Thescrewfeeddeviceisusedtopushthe workpiece againstthebandsawbladeinadirectionparalleltotheblade. Thefeedscrewmaybeapplieddirectlytotheworkpiece,ormaybeusedto pushtheworkholdingjawdeviceinwhichtheworkpiececanbepositionedat variousangles. (c) TheWorkHoldingJawDevice.Theworkholdingjawdevice(figure17 onthefollowingpage)canbeconnected,onsomemachines,tothepowerfeed toproducestraightlinecuts. (d) The Angular Blade Guide Attachment. The angular blade guide attachmentisusedforstraightlinesawingwhentheworkpiececannotbecut inthenormalmannerbecauseitistoolargeortoolongtoclearthecolumn ofthebandsawmachineframe.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 (2) CurveSawing. Curvesawingisperformedeitherbyusingthedisk cuttingsawattachmentorbyhandguidingtheworkpiece. FIGURE17.WORKHOLDINGJAWDEVICE.

(a) SelectingtheBlade. Caremustbetakentoselectabandsawblade oftheproperwidthfortheradiusorcurvetobecut. Ifabladeistoo widefortheradius,theheelofthebladewillpressagainsttheouteredge ofthekerf(figure18onthefollowingpage).Whentheheelcontactsthis edge,anyfurthertwistingoftheworkpieceinanattempttocutasharper radiuswilltwistthebandsawbladewithoutcuttingasharperradius. (b) CuttingtheCurve.Oncurvecutting,lesspressuremustbeapplied totheworkpiecethanonstraightlinecutting.Thesmallerthecurve,the morecaremustbeexercised.Itshouldbeunderstoodthatwhenanymaterial is cut with a flexible bandsaw blade, the blade deflects to the rear in proportion to the amount of pressure applied to the workpiece. This deflection,

26

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 referredtoas"drag,"willnotaffectastraightlinecutbecausethesides ofthebladeremainparalleltothecut. However,whencurvesarecuton thebandsawmachine,thedragwillcausea"belly"inthecutsection. To reducethebellytoaminimum,thedragmustbereducedtoaminimum,and this can only be done by reducing the pressure applied in feeding the workpieceintotheblade. FIGURE18.CURVELIMITATIONS.

(c) CurveSawingatanAngle. Whensawingatananglewiththetable tilted,acurveorradiuswillbeshapedlikeaconesection,withalarger radiusononeworkpiecesurface,andasmallerradiusontheotherworkpiece surface. Itisveryimportantwhencuttingatanglesthatthesmallerof thetworadiibeusedtodeterminethebandsawbladesize. Figure19(on thefollowingpage)showsachartofrecommendedbandsawwidthsforminimum radiitobecut.Therecommendationson

27

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 thisradiichartarebasedonsawingrelativelythinstock.Useanarrower bladethanrecommendedwhensawingstockmorethanoneinchthick. FIGURE19.MINIMUMRADIICHART.

(3) ContourSawing.Contoursawingistheprocessofcuttingshapesin whichthedirectionofthecutmustbechangedatintervals. Holeslarger indiameterthanthewidthofthesawblademustbedrilledateachcorner where a change of direction of the bandsaw blade will occur. After the shapeiscuteitherbysawingawayfromtheholeorsawingtowardthehole, and the slug or waste material has been removed, the corners should be finishedbyfilingornotching. Thebandsawbladeshouldnotbeusedfor theseoperationsbecausethebladewillbowandcutunevenly. (a) SawingAwayFromtheHole.Tosawawayfromtheholeonalinenext tothehole,thebandsawblademustcutawayfromthecenterofthehole,or thebladewillbowandcauseabellyinthecut.Twomethodscanbeusedto accomplish this. In the first method, to start the cut, a curve is cut outwardfromtheholetomeetthe

28

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 layoutline,leavingapieceofexcessmetalwhichcanberemovedlaterby filing(figure20).Inthesecondmethod,asectionofmetalisnotchedout with a saw blade by several short cuts to give the blade clearance for startingthecutalongthelayoutline(figure21). FIGURE20.SAWINGAWAYFROMTHEHOLEMETHOD1.

FIGURE21.SAWINGAWAYFROMTHEHOLEMETHOD2.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 (b) Sawing Toward the Hole. Sawing toward the hole is properly accomplishedintwocuts.Thefirstofthesecutsisshowninfigure22and thesecondisshowninfigure23. FIGURE22.SAWINGTOWARDTHEHOLEFIRSTCUT.

FIGURE23.SAWINGTOWARDTHEHOLESECONDCUT.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 c. InternalSawing. Internalsawingisperformedinthesamewayas contoursawing,exceptthatthebandsawbladecannotstartcuttingfromthe edge of the workpiece but must start cutting from a drilled hole in the workpiece(refertofigure16onpage21).Withthepatternlaidoutonthe workpieceandwiththestartingholedrilled,anunweldedbandsawbladeof theproperlengthisinsertedthroughthestartinghole.Thenthetwoends ofthebladearebroughttogetheratthebuttwelderofthebandsawmachine. Thebladeisthenweldedintoacontinuousband.Thebandsawbladeisthen installedontothebandsawmachine.Whenthesawingoperationiscompleted, thebandsawbladeiscutsothatitcanberemovedfromtheworkpiece. d. CuttingandWeldingtheBand. Wheninstallingabandsawblade,or when cutting and rewelding the blade for internal sawing operations, the bladeandtheweldermustfirstbeproperlyprepared;thenthebladecanbe welded.Followthisproceduretocutandweldabandsawblade. NOTE In the description that follows, the model 26121M bandsaw machine with integral welder is used as an example. The proceduresforweldingabandsawblade aresimilarforallmodels. (1) General. Thebuttwelderonthemodel26121Mbandsawmachineis capableofwelding3/4inchwideby.032gagecarbonorDartsawbands.The twoclampingjawsofthewelderholdthebuttedbandendstogether. When theweldingswitchleverispressed,anelectriccurrentisinducedthrough thebuttedendsoftheblade,creatingenoughheattosoftenthemetaland jointheends.Pressingtheweldinglever(figure24onthefollowingpage) also releases a spring which causes the jaws to force the band ends together.Whenthemovablejawhasmoved.065inchestowardthestationary jaw,theelectriccurrentisautomaticallycutoff.Thespringforceonthe jawsisreleasedwhentheweldingleverisreleased.

31

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE24.WELDERCONTROLS.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 (2) PreparingtheBlade. First,thesawblademustbecuttolength. Usingabladeshearwillensurethatthebladeendsareflat,square,and smooth.Ifsnipshavebeenusedtocuttheblade,theendsmustbesquared beforewelding.Thisisdonebygrindingtheendsoftheblade.Bothends of the sawbladeshouldbe groundinoneoperation. Holdingtheends so thattheteethpointinoppositedirectionsduringgrindingwillensurethat thetwoendswillmatchperfectlywhenturnedover,regardlessoftheangle ofgrinding.Thenbladeendsmustthenbecarefullycleaned.Thepartof eachbladethatcomesintocontactwiththewelderjawsmustbefreeofall dirtoroil.Anydirtoroilonthebladeorwelderjawswillpreventgood electricalcontact. (3) PreparingtheWelder. First,cleanthewelderjaws. Onthemodel 26121M bandsaw machine, the integral butt welder has a jaw upset force selector(refertofigure24onthepreviouspage),locateddirectlyabove the stationary jaw. The jaw upset force selector provides a variable controlsincewidersawbandsneedgreaterupsettingforcebetweenthejaws than narrow bands, and since too much force on small bands will cause climbing or overlapping. In preparing to make a weld, the jaw upsetting forceselectorcontrolshouldbesettothecorrectpositionforthewidth ofthesawbladebeingwelded. (4) SawBladeAlignmentBeforeWelding.Beforemakingtheweld,thesaw bladeendsmustbealignedsothatthebladewillbestraightafterwelding. Ifinternalsawingistobedone,thebladeisinsertedthroughthestarting holeinthework.Thentheendsofthesawbladearebroughttothewelder tobeclampedintothejaws.Alignthebladeusingthesesteps: (a) Insert the saw blade between the jaws with the back of the blade against the back of the jaws, lining up the blade so that it will be straightafterwelding. (b) Thebladeendsshouldmeetinthecenterofthejawgapwithoutany offseteitherinthicknessoracrossthewidth(figure25onthefollowing page). If the ends are clampedinanoffsetmanner,anoverlapping weld willresult.Thistypeofweldwillhavetobegroundtoomuch,resulting inaweakweld.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1

FIGURE25.SAWBLADEALIGNMENT.

(c) Ifthecontactacrossthewidthisnotcompletewhentheendsare clampedinthejaws,removeoneendandrecutit. Amisalignedjointwill causeanincompleteweld. (d) Afterthebladeendsarelinedup,clampthemsecurely,butnotso tightlyastoharmtheset,betweenthewelderjaws. (5) MakingtheWeld.Afterthebladeendshavebeenaligned,pressand holddowntheweldlever(refertofigure24onpage32)tomaketheweld. Thelevershouldbehelddownuntiltheweldhascooled.Thestationaryjaw clamp should be released before the weld lever is released. This will preventscoringthewelderjawsurface.Thenreleasetheweldlever.When the lever is released, the butt welder mechanism and electrical switches willbeautomaticallyrecocked,andthebandwillbereadytobeannealed. Removetheweldedsawband. Twogeneralstatementsaboutweldingtheband shouldbenoted: (a) Cutouttheoldweldaseachnewweldismade.Sinceonlyoneweld isrecommendedinasawband,usethebladesheartocutawaysmallportions oftheendsoftheoldweld. Sincetheweldingoperationusesupnomore than1/16inchoftheband,itwillnotshortenthebandappreciably,even after several welds have been made. Startingwithafullsizesaw band, approximatelythreetofourinchesofbandcanbeusedinmakingwelds

34

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 beforethebandwillbetooshorttofitoverthemachinewheels. (b) Ifitisfound,aftermakingtheweld,thattheteethoftheband pointinthewrongdirection,itcanbereversedbyturningthebandinside out. However,thiscannotbedonewhenthebandisweldedthroughapiece ofmaterialforinternalsawing.Inthiscase,thesawbandmustbecutand welded. (6) CleaningUpAfterWelding.Itisimportantthatthewelderjawsbe keptcleanatalltimes.Thejawsandinsertsmustbewipedand/orscraped cleanaftereveryweld. Doingthiswillmaintainthestrengthandfatigue characteristics of the band by holding proper alignment, preventing flash frombecomingembeddedintheband,andpreventingshortsorpoorelectrical contact. (7) InspectingtheWeld. Whenthebandisremovedfromthewelder,it shouldbeinspectedcarefully. Thecoloroftheupsetmaterialaroundthe weldshouldbebluegray,andofequalintensitythroughout.Thespacingof theteethshouldbeuniform,andtheweldshouldbelocatedinthecenterof thegullet. Majorjawmisalignmentiseasilynotedatthistimefromthe weldappearance. Figure26showsseveraltypesofdefectivewelds. Ifa weldisimperfect,someof FIGURE26.DEFECTIVEWELDS.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 thepossiblecausescanbefound,ifneeded,inTM9341922810,beginning onpage46(orinthetroubleshootingsectionoftheTMforthewelderbeing used). (8) GrindingtheWeldedBand. Afterwelding,thebandmustbedressed toremoveexcessmetalorflashfromtheweld.Grindtheweldedareadown tothesamethicknessastherestoftheband. Theweldshouldbeground withtheteethfacingout(figure27). Caremustbetakenduringgrinding soasnottohittheteeth,nottogrinddeeperthanthethicknessofthe band, and not to burn or overheat the weld area. The weld should pass freelythroughthegageabovethegrindingwheel. CAUTION Use care in handling the band; the weld is brittle becauseithasnotyetbeenannealed. FIGURE27.GRINDINGTHEWELD.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 (9) AnnealingtheWeldedBand.Directlyabovethegrindingwheelisthe annealing pushbutton. When the band is heated up in the welding and grinding process, the steel at the point of the weld airhardens and is brittle.Therefore,itisnecessarytoannealtheweldbyreheatingitand allowingittocoolslowly. Thisreturnsthebandtoanapproximationof itsoriginaltemper.Usethesestepstoannealtheweld: (a) Cleanthewelderjaws. (b) Pressthespringclipbehindtheweldlever,andmovetheleverup alltheway. (c) Clampthebandjustbackoftheteeth. (d) SettheANNEALHEATselectorswitch(refertofigure24onpage32) ateitherthe1/16inchto1/2inchorthe5/8inchto3/4inchposition, accordingtothewidthofthebladebeingannealed. (e) Thenextstepintheannealingprocessdependsonthetypeofblade beingannealed.Itisveryimportantthatthisstepbeperformedcarefully: 1 CarbonBlades. Ifacarbonbladeisbeingannealed,pressandjog theannealswitchpushbuttonuntiltheweldisadullcherrytocherryred in color. Then allow the bladetocoolslowlybydecreasingthejogging frequency. 2 DartBlades.ForaDartblade,heatthebladeslowlyuntiltheweld becomesadeepbluecolor. Continuetoheatbyjoggingtheannealswitch pushbuttonuntilthewidthofthebluecolorisonehalfthelengthofthe bandexposedbetweenthejaws. Donotoverheatorthetemperoftheband adjacenttotheweldwillbedamaged.Coolquicklybyreleasingthebutton. e. GeneralFilingOperations. Filingoperationsareperformedonthe bandsaw machine using aband fileandthebandfileattachment. As with sawingoperations,thequalityoffilingandtheeconomicalwearoftheband filedependuponproperselectionoffilesandfilingspeedsfordifferent materialsandconditions.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 (1) Band File Attachment. Most bandsaw machines have a band file attachment(figure28)topermittheuseofbandfilesonthemachine. A typical band file attachment consists of a band file guide and upper and lowerguidesupports. Thesesupportsattachtotheframeandpostofthe bandsawmachinetoprovidearigidtrackuponwhichthebandfilecanride. A special filing filler plate isprovidedtoadaptthetableslot to the extrawidthanddepthrequiredforthebandfileandthefilebandguide. Mostbandfileattachmentshaveeitheradjustableguidesandguidesupports, ortwoormorefilebandguides,sothatdifferentwidthfilebandscanbe accommodated. FIGURE28.BANDFILEATTACHMENT.

(2) FileBands.Thebandsawmachineisadaptedforfilingbyuseofthe bandfileattachment.Abandfileisfittedoverthedriveandidlerwheels inplaceofthebandsawblade.Bandfiles(figure29onthefollowingpage) consist of many interlocking file segments that are riveted to flexible steelbands.Thesebandsareattachedtoeachother,endtoend,toforma continuousband.Thefilesegmentsareattachedtothesteelbands

38

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 insuchawaythattheywillformacontinuousfilingsurfacewhenheldina straight line, but will separate from each other as they move around the idleranddrivewheels.Thebandfileattachmentprovidesasupportbehind thefileabovethetable,sothatthebandfilecannotbeforcedbackwardby thepressureoftheworkpieceasitisfiled. FIGURE29.ATYPICALBANDFILE.

(a) CutofFileTeeth.Mostfilesareclassedassinglecutordouble cut files according to the kindofteeth. Singlecutfileshaverows of parallelteethextendingacrossthefaceofthefileatanangle. Double cutfileshavetworowsofparallelteethwhichcrosseachother.Thefirst row,usuallycutatabouta45angle,iscoarseranddeeperthanthesecond rowwhichisgenerallycutatanangleoffrom70to80.Bandfilesare alwaysofthedoublecuttype.Doublecutfilesofmediumpitcharecalled bastardcut files. These files usually have between 12 and 24 teeth per inch. Bastardcutbandfilesarecommonlyusedforfilingsteelandother hard metalsonthebandsawmachine. Shortanglecutfilesaredoublecut filesinwhichthetworowsofteethhavebeencutatshorteranglesthan those of the bastardcut file. Short anglecut files are usually coarse pitch,having10or11teethper

39

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 inch. Shortanglecutbandfilesarecommonlyusedforfilingsoftmetals onthebandsawmachine. (b) Band File Shapes. Band files are manufactured in flat and oval shapes. Flatbandfilesare usedformostfilingjobs. Ovalband files have a curved face, and are used for filing inside curves and contours. Bandfilesaremadein1/4,3/8,and1/2inchwidths. (c) SelectionofBandFiles. Bandfilesshouldbechosenonthebasis ofworkpiecethicknessandthekindofmaterialtobefiled.Ingeneral,as theworkpiecebecomesthicker,thefileshouldbecoarser.Thisisbecause largertotalchipaccumulationfromthickpiecesrequiresadditionalspace forthechipsbetweentheteeth.Onthinsheetmetal,afinepitchfileis requiredtopreventchatter.Narrowerpitchfilesareusedfortoughcarbon andalloysteels;widerandcoarserpitchfilesareusedforsofter,more freecutting materials such as cast iron and nonferrous metals. Table 5 providesaguideforselectingtheproperfileforspecificmaterials. If sheetmetalistobefiled,afinertoothfileshouldbeused,ifnecessary, toreducechatterandproduceabetterfinishontheworkpiece. TABLE5.SELECTIONOFBANDFILES.

(d) CareandCleaningofBandFiles.Theparticlesofmetalremovedby thefileoftenlodgeinthefileteeth,reducingthecuttingefficiencyof thefileandaffectingthequalityofthefinish. Ifhardmetalparticles arelodgedinthe

40

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 file teeth, they may scratch the workpiece. When steel is to be filed, chalkcanberubbedintothefilebeforefiling;thechalkwillreducethe tendency for hard particles to adhere to the file. The file should be cleaned often, using a stiff brush or a file card. The brush should be moved in the direction of eachcutofthefiletodislodgeallparticles hiddenbetweentheteeth. (3) Band Filing Speed. Band files should be run at relatively slow speeds as compared to speeds used for bandsawing. In general, the best filingspeedsarebetween80and150feetperminute(fpm).Table6lists therecommendedfilingspeedsforbandfiling. Notethat,ingeneral,the slowerspeedsareusedforfilinghardermetals,andthefasterspeedsare usedforfilingsoftermetals. TABLE6.BANDFILINGSPEEDS.

(4) Band Filing Feeds. Work pressure on the band file should not be excessive. Medium pressure applied against the band file moving at the properspeedwillproducecurledchipswhichwillnotclogthefile.Heavy pressurewillcausecloggingandcancausethefiletobreakorthemachine tostall.Alightpressureshouldbeusedforfinishfiling,withaslow, sidewaysmotionthatwillnotleaveverticalfilemarksontheworkpiece.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1

NOTE The procedures used for band filing using bandsaw machinemodel26121Marepresentedhereasanexample ofbandfilingprocedures.Bandfilingproceduresare similarforallbandsawmachinemodels. (5) Setting Up the Machine for Filing. To set up the model 26121M bandsawmachineforeitherinternalorexternalfiling,performthesesteps: (a) Ifthemachineissetupforsawing,removethesawband. (b) Removethetablecenterdiskandpostsawbandguard. (c) Removethesawguidesfromthemachine. (d) Mountthefileguidesupportonthelowerkeeperblock,makingsure theproperwidthofslotforthefilebandisbeingused. (e) Lowertheupperposttotheproperworkthickness. Thisthickness shouldnotexceedtwoinchesfora1/4inchfilebandandfourinchesfor 3/8and1/2inchbands. (f) Install the upper file guide (figure 30 on the following page), lockingitfirmlytothepostwiththeknurledthumbscrews. (g) Installthespecialtablecenterdiskforfiling. (6) JoiningtheFileBand.Tojointhefileband,takeoneendofthe file band in each hand, with the yellow painted end (figure 31 on the followingpage)inthelefthand.Holdthefileendsatrightangleswith thefilingsurfaceup.Depressthetipofthespringsteelbandheldinthe righthandwiththelockrivetoftheyellowsegmentheldinthelefthand. Allowtherivetheadtoslipintotheslottedhole. Slidetherivethead into the small end of the slot. Straighten the file band, allowing the springsteelendtosnapoverthedowel. Makesurethattheendsofthe bandareflushbeforerunningthebandonthemachine.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 FIGURE30.SETTINGUPFORFILING.

FIGURE31.JOININGTHEFILEBAND.

(7) TrackingandTensioningtheFileBand. Thefilebandsarealigned on the wheels in the same way as is used in tracking the saw bands, describedinparagraph4a(4)beginningonpage17.Thebandcanbemadeto run on the crown of the wheel by tilting the upper wheel with the tilt control.Whenproperlytracked,thefilebandshouldrunfreelyinthefile guidechannel.Thetensionofthefilebandshouldbeadjustedtothesame 43

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 tensionasthatusedfora1/8inchwidecarbonsawband.Toomuchtension willcausethefilesegmentrivetstobreakwhenheavyfilingpressureis applied. While it might seem, at first, that better filing results are obtainedwithexcesstighteningofthefileband,thiswillnotbethecase inthelongrun. Mostaccuratefilingcanbeobtainedwiththelightband tension. Checkthefilebandtoseethatitisinalignmentandwillpassfreelyover the channelinthefileguide. Thenshiftthemachineintolowgear and startthedrivemotor.Observethefileband(figure32)tobesurethatit istrackingproperly. FIGURE32.TRACKINGTHEFILEBAND.

CAUTION File segment must travel with the riveted section down; if not, injury to operator and damage to file bandandbandsawwilloccur. (8) The Filing Operation. During the filing operation, the correct combination of speed and pressure will produce curled chips. The best filingspeedsarebetween80and150fpm. Forinternalfiling,unlockthe bandandrunitthroughtheopeningintheworkpiece;thenreassemblethe band.Keepthefilesclean.Donotfilewhenthe

44

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 teeth are loaded. Loaded files cause bumpy filing and scratch the workpiece. Excessive filing pressureswhenthefilesegmentsareclogged withchipswillcausethefileteethtostripout.Useafilecardorbrush tocleanthebandbeforereturninganyfilebandtothestoragecabinet. (9) Removing the File Band. To remove the file band, release the tensionbyloweringtheupperwheel,andslipthebandoffthewheels. To separatethebandafterithasbeenremovedfromthewheels,performthese steps: (a) Holdthebandatthejointwithbothhands,withtheyellowsegment inthelefthand. (b) Bendthejointtonotmorethana12inchradius,exposingthejoint slot. (c) Usingtheforefingerofthelefthand,depressthefrontendofthe yellowfileband. Withthethumbandforefingeroftherighthand,disengagethedowel. (d) Slidethelockrivettotheopenendoftheslotandliftoff. (e) Forstorageafterremoval,thefilebandshouldnotbecoiledinto morethanthreeloops. f. General Polishing Operations. Polishing bands and a polishing attachment are provided with the bandsaw machine so that light polishing operationscanbeperformed.Thepolishingbandsareintendedprimarilyfor removingsawmarksonthecutedgesofworkpieces. (1) Polishing Attachment. A polishing attachment (figure 33 on the followingpage)isprovidedwithmostbandsawmachinestoallowthemachine to be used for polishing. The attachment, similar to the band file attachment, provides support for the polishing band, together with the polishingbandplatewhichissupportedbetweenthepostandframeofthe bandsawmachine. Thepolishingbandplateactsasasolidbackingforthe polishingbandtopreventstretchinganddistortingthepolishingbandwhen theworkpieceisheldagainstit.Apolishingbandfillerplateisusedto fillthetableslotsotheworkpiececanbesupportedclosetothepolishing band.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 (2) PolishingBands. Whenthepolishingattachmenthasbeeninstalled on the bandsaw machine and the bandsaw blade has been replaced by the polishing band, polishing operations can be performed on the bandsaw machine.Thepolishingbandisusuallyoneinchwide,andhasaheavy FIGURE33.POLISHINGATTACHMENT.

fabric backing. Polishing bands are manufactured to withstand high finishingandpolishingtemperatures. Abrasivebandsaremountedoverthe wheels in the same manner as saw bands; however, a rigid backup support which has a graphite impregnated facing is used. This polishing guide support(figure34onthefollowingpage)ismountedtothepostinplaceof thesawguides. (a) TypesofPolishingBands.Polishingbandsforbandsawmachinesare usuallysuppliedinthreegrainsizesofaluminumoxideorsiliconecarbide abrasive. Number 50 grain (coarsemedium) is used for light grinding operations, soft materials, and heavy stock removal with the bandsaw machine. Number 80 grain (mediumfine) is used for coarse polishing operationsandgeneralsurfacefinishing.

46

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 Number120(ornumber150)grain(fine)shouldbeusedforfinepolishing operations. The bands are preformed in continuous bands in appropriate sizestofitthebandsawmachine. FIGURE34.BANDPOLISHINGGUIDE.

(b) Selection of Polishing Bands. Polishing bands should be selected according to the particular job to be performed. For general removal of tool marks and for smoothing edges, the number 50 grain polishing band shouldbeused. Thisbandwillremovesmallamountsofmetalbygrinding, andisnot,inthetruesenseoftheword,apolishingband. Whenfiner grain polishing bands are used on the bandsaw machine, soft metals like aluminumorcastironshouldnotbepolished,orthebandwillquicklyfill withmetalparticles,reducingthecuttingactionofthepolishingband. (3) PolishingSpeeds.Polishingbandsshouldbemovedatspeedsbetween 75and260feetperminute(fpm),thefasterspeedsbeingusedforsofter materialsandtheslowerspeedsbeingusedforhardermaterials. Theband speedforpolishingisdeterminedbytheapplication. Forgrinding,a50 grainpolishingbandshouldbeusedatspeedsbetween50and300fpm. For general/coarse

47

BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 polishing,a80grainpolishingbandshouldbeusedatspeedsbetween850 and1000fpm.Forfinepolishing,a120(or150)grainpolishingbandcan beusedatspeedsbetween850and1500fpm. (4) Polishing Feeds. Feeds shouldbe light forpolishing operations. Useaslow,sidewaysmotionsothatthepolishingbandwillleavenomarks on the workpiece. Ifthe banddoesnotremovethetoolmarksquickly, a coarserpolishingbandshouldbeused. NOTE The procedures used for polishing using bandsaw machinemodel26121Marepresentedhereasanexample of band polishing procedures. Band polishing proceduresaresimilarforallbandsawmachinemodels. (5) SettingUpforBandPolishing. Setupforbandpolishingwiththe model26121Mbandsawmachineusingthesesteps: (a) Removethetablecenterdisk. (b) Mountthepolishingbandguidebackupsupporttotheloweradapter asforfiling. (c) Lowertheposttofourinchesfromthetable.Thenmounttheband polishingguideonthepostandsecureitwiththetwothumbscrews. (d) Occasionally,graphitepowdershouldberubbedintotheguidefabric tolubricateandtoincreasethelifeofthepolishingbands. (e) Mountpolishingbandtotravelindirectionofarrowprintedonthe backsideofpolishingband.Thecorrectpolishingbandtensionisthesame asthatusedfora1/16inchwidecarbonsawblade. (f) Installthespecialcenteradapterplateinthetable. (g) Donotusecoolantwiththepolishingband.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/TASK 1 5. Conclusion

Themetalcuttingverticalbandsawmachinehasmanyuses. Itcanbeused forstraightorcontouredsawing. Itcanmakeinternalorexternalcuts. Itcanalsobeusedforfilingandpolishing.Understandinghowthebandsaw machine is used will help in performing the repair, adjustment, and troubleshootingproceduresthatwillbedescribedinlessontwo.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/PE 1 PRACTICALEXERCISE1 1. Instructions

Readthescenarioandrespondtotherequirementsthatfollowthescenario. 2. Scenario

You have been assigned to a military advisory group (MAG) and will be travelingtoRiyadh,SaudiArabia.ThepurposeoftheMAGassignmentisto familiarizeagroupoftheirrepresentativeswiththeuseandmaintenanceof certainitemsofpowerequipment.Itwillbeyourjobtomakesurethatthe Saudirepresentativehasenoughknowledgeofthebandsawmachinesavailable to his people so that the machines may be safely used and properly maintained. 3. FirstRequirement

In an effort to introduce them to the capabilities of models of bandsaw machinesthatmaybeavailabletothem,youarepreparedtodiscuss,among others,thefollowingattachments: Choose from the list the accessorythatisbestdescribedbyeach of the followingstatements: Angularbladeguide RipFence Diskcutting Miterguide Screwfeed a. The____________________________isadeviceusedforprecisioncontour sawingofheavywork.Itisahandoperatedmethodoffeedingtheworkpiece intothebladeorfile. b. The_____________________________attachmentisadeviceusedtosupport andguideworkpiecestothebandsawbladesothattheworkpiecemaybecut ataspecificangle.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/PE 1 c. The _______________________ attachment twists the bandsaw blade so that large or long workpieces that would not normally clear the bandsaw machinecolumncanbecut. d. The _______________________ attachment permits the cutting of true circles,eitherinternallyorexternally. e. 4. The________________________helpsinmakingeven,straightcuts. SecondRequirement

Defineordescribethefollowing: a. b. c. d. e. 5. Kerf Rakersetting Pitchofteeth Annealing Bastardcutfiles ThirdRequirement

During theannealingprocess,thewelderandbladehavebeenproperlyset up.Describetheannealingprocessonthemodel26121Mbandsawmachinefor (a)carbonbladesandfor(b)Dartblades.

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BANDSAW OPERATIONS - OD1646 - LESSON 1/PE 1 LESSON1.PRACTICALEXERCISEANSWERS 1. FirstRequirement a. Screwfeeddevice b. miterguide c. angularbladeguide d. diskcuttingattachment e. ripfence 2. SecondRequirement a. Akerfisacutmadebyabandsawblade. b. The raker setting is the setting of the teeth for most bandsaw machines. Raker tooth blades haveonetoothbenttotheright,the next toothbenttotheleft,andthethirdtoothsetstraight. c. The pitch of bandsaw blade teeth is the number of teeth per linear inchoftheblade. d. Annealing is the process or reheating metal and allowing it to cool slowly,therebyreturningittoanapproximationofitsoriginaltemper. e. bastardcut files are doublecutfilesofmediumpitch,usuallyused forfilingsteelandotherhardmetals. 3. ThirdRequirement (a) Carbon Blades. If a carbon blade isbeing annealed onthe model 26121Mbandsawmachinewelder,pressandjogtheannealswitchpushbutton until the weld is a dull cherry to cherry red in color. Then allow the bladetocoolslowlybydecreasingthejoggingfrequency. (b) DartBlades. ToannealaDartblade,heatthebladeslowlyuntil theweldbecomesadeepbluecolor.Continuetoheatbyjoggingtheanneal switchpushbuttonuntilthewidthofthebluecolorisonehalfthelength ofthebandexposedbetweenthejaws.Donotoverheatorthetemperofthe bandadjacenttotheweldwillbedamaged. Coolquicklybyreleasingthe button.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 LESSON2 BANDSAWMAINTENANCEANDTROUBLESHOOTING TASK1. Describethemethodsusedtorepairandadjustthebandsaw.

CONDITIONS Within a selfstudy environment and given the subcourse text, without assistance. STANDARDS Withinonehour REFERENCES Nosupplementaryreferencesareneededforthistask. 1. Introduction

Aknowledgeoftheproceduresforproperlyoperatingabandsawmachinewill behelpfulinlearninghowtomaintainthemachine,andwillbeparticularly useful in learning to isolate the causes of malfunctions in bandsaw machines.Inthistask,theproceduresrequiredforperformingmaintenance onthreemodelsofbandsawmachineswillbediscussed. Thesemodelsare: model16120,model26121M,andmodel26141. Inthesecondtaskofthislesson,thetroubleshootingproceduresforthese threebandsawmodelswillbedescribed. 2. MaintenanceProceduresfortheModel16120BandsawMachine

Maintenance procedures for the model 16120 bandsaw machine include replacing the wheel tires, checking and adjusting the wheel brushes, adjustingandreplacingdrivebelts,lubricatingtheheadassembly,cleaning and lubricating the variable speed pulley, and replacing the saw guide backup

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 bearing caps. Maintenance of the electric motor is accomplished by followingthemanufacturer'sinstructionslocatedonthetagattachedtothe motor. Lubricationrequirementscanbefound,whenneeded,inTM93419 22710,page27. a. WheelTires. Whenthetiresarecompletelywornout,theyshouldbe replaced. Replacethembylooseningthetirewithascrewdriver. Stretch the tire untilitcanbe removed. Scrapethewheelclean,andapply new cementbeforeinstallinganewtire. b. WheelBrushes.Thewheelbrushshouldbecheckedoccasionally.Ifit is worn so that it is no longer contacting the wheel face, loosen the adjustingscrewsandmovethebrushuptothewheel. Replacethebrushas required. c. Drive Belts. The belts driving the speed indicator and the input sheavewillstretchslightlyafterinitialuse.Thestretchofthebeltsis automatically taken up by the counterbalancing weight of the drive motor (figure35onthefollowingpage)onitsmountinghinge. (1) ReplacingtheBelts.Thebeltscanbeeasilyreplacedbyliftingup thedrivemotorandblockingitinplace.Afterthedrivemotorislifted andblocked,thebeltscanbeslippedofftheirpulleysandnewbeltscanbe installed. (2) Adjusting the Motor Bracket. The motor bracket (figure 35) is adjustedtocontrol"hopping"orclimbingofthedrivemotorinitsbelt. Adjust the bracket to just clear the motor plate when at its highest positionduringoperation. d. HeadAssembly. Theheadassemblyonthemodel16120bandsawmachine isshowninfigure36onpage56.Accesstotheheadassemblycanbeeasily gained by liftingtheupperwheelupandoutofthebracketonthe slide assembly(refertofigures35and36).Oilshouldoccasionallybewipedon the post, andthepostshould berunupanddownthroughtheslide block severaltimes.Theupperwheelslideandbandtensionscrewshouldbeoiled monthly.Thewheelbearingsaresealedandlubricatedforlife.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1

FIGURE35.MODEL16120MAINTENANCE LOCATIONSREARVIEW.

e. Variable Speed Pulley. Every six months, the variable speed pulley unitshouldberemoved.Itshouldbewashedandcleanedwithsolvent.Then it should be reoiled and installed. The pulley shaft bearings are lubricatedfromanoilcup(figure37onthefollowingpage)intheshaft end. The center sheave, which floats sideways as well as rotates, is lubricated by a wick which is immersed in oil which travels through the hollowshaftfromtheoilcup. Checktobesurethecentersheaveofthe pulleyisfreetoshiftsideways. Thefacesofthevariablespeedpulley shouldbecheckedforscoringwhichcoulddamagethebelts.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 FIGURE36.THEHEADASSEMBLY(MODEL16120).

FIGURE37.SECTIONALVIEWOFTHEVARIABLE SPEEDPULLEYMODEL16120.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1

CAUTION Do not overlubricate, sinceoilwillcoatthebelts andcauseslippage. f. Saw Guides. When the saw guide backup bearing caps become worn or grooved, they should be replaced. On the 1/16 to 1/2 inch guides, the bearings, caps, and shaft are replaced as a unit. When replacement is required,loosenthesetscrewholdingthebearingassembly. Thenreplace thecompleteassembly.Onthe5/8to3/4inchguides,thebearingcapand shaftarereplacedbyremovingthesnapringandpullingoutthebearingcap and shaft. Thebearingsare installedwithalightpressfitandcan be easilyreplaced.Bothtypesofbearingsarepermanentlylubricatedandneed nofurtherlubrication. g. Air Pump. The rotary air pump on the model 16120 bandsaw machine should not be oiled. The vanes are made of plastic, and oil tends to destroy them. Use powdered graphite very sparingly. This graphite is forced into the pump through the air inlet while the pump is in motion. Removetheaircleanerandwashitingasolineorsolventmonthly. 3. MaintenanceProceduresfortheModel26121MBandsawMachine

Maintenance procedures for the model 26121M bandsaw machine include adjusting and replacing the wheel brushes, replacing the wheel tires, cleaning and lubricating the variable speed pulley, replacing the saw guides,adjustingandreplacingthedrivebelts,adjustingthebandtension indicatorontheheadassembly,andflushingthetransmission.Theelectric motorismaintainedfollowingthemanufacturer'sinstructionslocatedonthe tagattachedtothemotor. a. WheelBrushes. Thewheelbrushesshouldbecheckedoccasionally. If a brush is worn so that it is no longer contacting the wheel face, the adjustingscrewsshouldbeloosenedandthebrushmoveduptothewheel.A wornbrushshouldbereplaced. b. Wheel Tires. To replace a wheel tire (figure 38 on the following page),followthisprocedure:

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 FIGURE38.REPLACINGAWHEELTIREMODEL26121M.

(1) Removethetworetainersfromthefrontofthebandwheel. (2) Removethetireretainingrings. (3) Drive the tire off the wheel. If necessary, saw off the steel backing. (4) Mountnewtiressothatthetwonotchesinthesteelbackingarein alignmentwiththetwotireretainers. (5) Putthenewtireonwithlighttapsofasoftfacedhammer,rotating thewheelabout30degreesaseachtapismade,untilthetireisagainst theflangeofthewheel. (6) Replacetheretainersandthetireretainingrings. c. Variable Speed Pulley. Every six months, the variable speed pulley unit(figure39onthefollowingpage)shouldberemovedsothatitcanbe washedandcleanedwithasolvent.Afterithasbeencleaned,itshouldbe reoiledandinstalled.Checkthepulleytoseeifthecentersheaveisfree toshiftsideways. Thevariableshaftbearingsarelubricatedfromanoil cupintheshaftend.Thecentersheave,whichfloats

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 sidewaysaswellasrotates,islubricatedbyawickwhichisimmersedin oil. This oil travels through the hollow shaft from the oil cup. The variablespeedpulleyfacesshouldbecheckedforscoringwhichcoulddamage thebelts. FIGURE39.VARIABLESPEEDPULLEYMODEL26121M.

CAUTION Donotoverlubricatethepulley. Excesslubrication couldcoatthebeltsandcauseslippage. d. SawGuides.Thesawguidebearingsarereplacedbyremovingthesnap ringandpullingoutthebearingcapandshaft.Thebearingsareinstalled withalightpressfit,andcanbeeasily 59

BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 replaced,whenrequired.Thebearingsaresealedandpackedforlifewitha speciallubricant. e. DriveBelts. Thebeltsdrivingthevariablepulleyandinputsheave will stretch slightly after initial use. The stretch of the belts is automaticallytakenupbythecounterbalancingweightofthedrivemotoron itsmountingplate(figure40). Themotorismountedonapivotedplate. Thelargespringtotheleftofthepivotisadjustedtocounterbalancethe weightofthemotoronthedrivebelts. FIGURE40.BELTDRIVESYSTEMMODEL26121M.

(1) AdjustingtheBelts. Toadjustthebelts,adjustthenutsonthe counterbalancespringsothatthereisenoughtensiononthedrivebeltsto prevent slippage. If the motor is insufficiently counterbalanced, unnecessary wear on the variablepulleysheaves,bearings,andshaft will result.Toomuchcounterbalancewillcausethemotorto"climbthebelt"or "hop"excessively. (2) Changing the Belts. To change the belts on the model 26121M bandsawmachine,performthesesteps:

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 (a) Loosen the air pump mounting bolts enough to move the pump and removethebelt. (b) Tiltthepivotedmotorplate,andplaceablockunderit. (c) Afterthemotorplateisblocked,thetwodrivebeltscanberemoved andreplacedwithnewbelts. f. HeadAssembly.Thewheelbearingsaresealedandlubricatedforlife. Ifitisnecessarytoadjustthebandtensionindicator,firstloosenthe set screw clamping the wire leadingtotheindicator. Thentakeall the slackoutofthebandwiththebandtensioncontrol. Adjusttheindicator pointer to zero and lock the linkage arm to the wire. A more accurate calibrationcanbeobtainedbyusingabandtensionmeasuringinstrument. g. Transmission. The transmission should be drained, flushed, and refilledafterthefirstmonthofuse,andthenatleasteverysixmonths. Itshouldbefilleduntiltheoillevelisatthelevelofthefillerplug in the elbow. Use SAE number 20 oil. Check for seal leaks around the shafts. Anyroughoperation,vibration,loudorunusualnoisesshouldbe investigated immediately. It is recommended that the transmission be returned to the factory for repairs. Installing a new transmission correctlyisextremelyimportantbecauseofthecarefulalignmentinvolved. If the shifter plate has been removed for any reason, do not attempt to operatetheshiftlever. 4. MaintenanceProceduresfortheModel26141BandsawMachine Maintenance procedures for the model 26141 bandsaw machine include lubricationoftheheadassembly,adjustmentofthebandtensionindicator, replacement of the wheel tires, adjustment of the wheel brushes, and flushingthetransmission.Maintenanceoftheelectricmotorislimitedto themanufacturer'sinstructionslocatedonthetagattachedtothemotor. a. HeadAssembly.Thewheelbearingsaresealedandlubricatedforlife. Theupperwheelslideandthebandtensionscrewarelubricatedbygrease fittings.Occasionally,oilshouldbewipedonthe

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 post,andthepostshouldberunupanddownthroughtheslideblockseveral times. If it is necessary to adjust the band tension indicator, first loosenthesetscrewclampingthewireleadingtotheindicator. Thentake all the slackoutofthe bandwiththebandtensioncontrol. Adjust the indicator pointer to zero and lock the linkage arm to the wire. A more accurate calibration can be obtained by using a band tension measuring instrument. b. Wheel Tires. When the wheel tires are completely worn out, they shouldbereplaced.Thisisaccomplishedbylooseningthetirewithascrew driverandstretchingituntilitcanbetakenoff. Thewheelshouldthen bescrapedclean.Newcementmustbeappliedbeforeinstallinganewtire. c. WheelBrushes.Checkthewheelbrush(figure41)occasionally.Ifit is worn so that it is no longer contacting the wheel face, loosen the adjusting screws and move the brush up to the wheel. Replace the wheel brushasneeded. FIGURE41.ADJUSTINGWHEELBRUSHESMODEL26141.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 d. Transmission.Checktheoillevelofthetransmission(figure42)as required.Afterthefirstmonthofoperationandatleasteverysixmonths afterthat,thetransmissionshouldbedrained,flushed,andrefilled.Fill thetransmissiontothetopofthefillpipe,butdonotoverfill.Usehigh quality,rustandoxidationinhibited,mediumhydraulicandgeneralpurpose industrial oil, ASTM grade number 315. Check for seal leaks around the shafts. Anyroughoperation,vibration,loudorunusualnoisesshouldbe investigatedimmediately.Sinceinstallinganew FIGURE42.MODEL26141DRIVECOMPARTMENT.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 1 transmission correctly is extremely important because of the careful alignmentinvolved,itisrecommendedthatthetransmissionbereturnedto the factory when repairs are required. If the shifter plate has been removedforanyreason,donotattempttooperatetheshiftlever. 5. Conclusion

Itisobviousthatmanyofthemaintenanceproceduresforthethreebandsaw machines being described here are similar. A firm grasp of these maintenance procedures will be helpful in isolating faults when troubleshooting,asdescribedinthenexttask.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 LESSON2 BANDSAWMAINTENANCEANDTROUBLESHOOTING TASK2. CONDITIONS Within a selfstudy environment and given the subcourse text, without assistance. STANDARDS Withintwohours REFERENCES Nosupplementaryreferencesareneededforthistask. 1. Introduction Describetheproceduresfortroubleshootingthebandsaw.

Lessononeprovidedadescriptionoftheusesofabandsawmachineandthe propermethodsforoperatingaverticalbandsawmachine.Inthefirsttask oflessontwo,maintenanceproceduresforthreedifferentbandsawmachines werediscussed.Athoroughworkingknowledgeofoperationalandmaintenance procedures is required before troubleshooting procedures can be accomplished. This task will discuss the procedures used for isolating malfunctions(troubleshooting)forthesethreemodelsofbandsawmachines. 2. GeneralTroubleshooting

Whenaproblemoccursinequipment,fromthefailureofeitheramechanical or electricalcomponent,itisnecessarytounderstandhowtoisolatethe cause of the problem so that it can be fixed. Troubleshooting is the logical processusedtoisolatethecauseofamalfunctionbyidentifying thesymptoms,isolatingthefaultsothatcorrectiveactioncanbetaken.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 a. Identifying the Symptom. The identification of the symptom of a malfunction in one of the three models of bandsaw machines is merely a descriptive statementofwhatisgoingwrongduringanattempttooperate the machine. Examples might be: TRANSMISSION WILL NOT STAY IN GEAR or SURFACEFINISHONWORKTOOROUGH. b. IsolatingtheFault. Oncethesymptomhasbeenaccuratelydescribed, it is necessary to isolate the cause of the problem. This is done by performing steps in a logical sequence as described in the appropriate technical manual(TM). Thesefaultisolationstepsareorganizedsothat themostfrequentorobviouspossibilitiesarecheckedfirstandtherarer causesofthemalfunctionsymptomareperformedlast,ifthecauseofthe malfunctionhasstillnotbeenfound. c. Correcting the Fault. The fault isolation steps listed in the appropriate TM for any given symptom should be performed only up to the pointwhereafaultisfound.Thecomponentcausingtheproblemshouldthen bechecked,adjusted,orreplaced,andthebandsawmachinetestoperatedto ensurethattheproblemhasbeenfixed.Iftheproblemstillexists,fault isolation using the troubleshooting list should continue until test operation proves that the fault has been corrected. Usually, when troubleshootingthebandsawmachinemodelsdiscussedinthissubcourse,the fault remedy is selfevident. For example, if the fault isolation list requiresthatthetransformerbechecked,andthetransformerisfoundtobe bad,thenthetransformershouldbereplaced. Followingreplacement,test operation should be performed to confirm that the malfunction no longer exists. NOTE The emphasis of this task is to describe troubleshootingprocedures,i.e.,theisolationofthe causes of specific malfunctions in bandsaw machines. Since the corrective procedures for most of the problemsareselfevident,theywillnotbediscussed in detail in this subcourse. Whenperformingactual troubleshooting, always have the appropriate TM available,andfollowtheproceduresdescribedthere.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 3. TroubleshootingFaultSymptomsintheModel16120BandsawMachine

Themalfunctionsymptomsandtheirpossiblecausesforproblemsinthemodel 16120bandsawmachinearedescribedbelow.Asstatedearlier,theremedies forthesepossiblecauseswillnotbediscussedindetailhere.Operational solutionstoproblems,suchasselectingabladeoftheproperpitch,canbe foundinTM9341922710,pages8through26.Lubricationandmaintenance solutions for malfunctions can be found in TM 9341922710, on pages 27 through 31. This TM should always be available before actual repair or troubleshootingproceduresareperformed. a. Troubleshooting the Malfunction: MACHINE WILL NOT START. When the model16120bandsawmachinewillnotstart,threechecksshouldbemadein anattempttolocatethecauseoftheproblem. (1) First,checkthemainfusesandthecontrolcircuitfuse. Replace anyfusethatisdefective.Ifafuseisreplaced,trytostartthemachine toseeiftheproblemhasbeensolved.Ifthemachinestillwillnotstart, performthenextstep. (2) Check the reset on the band drive motor starter (if a starter is used). Starting and stopping the machine a number of times in quick succession, oranoverload,willtripthestarterheater. Afterlocating andcorrectingthetrouble,pushintheresetbutton. Iftheheaterrelay hasbeensetforautomaticoperation,itwillnotbenecessarytopushthe resetbutton,butwillonlybenecessarytowaitfortherelaytocool.Try startingthemachine.Ifthemachinewillnotstart,performthenextstep. (3) Checkthetransformer,andreplaceitifnecessary.Testoperateto ensurethattheproblemhasbeenfixed. b. TroubleshootingtheMalfunction:SEVEREMACHINEVIBRATION. Thereare threepossiblecausesforseveremachinevibration. (1) Checktoseeifthebandwheelsarebalanced. Ifthebandwheels are not balanced, machine vibration could result. Balance the wheels if necessary.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (2) If the band wheels are balanced, and vibration is still present, checktoseeifthevariablepulleycomponentsarebalanced. Iftheyare not balanced, vibrations could result. Balance the components of the variable pulley, if needed. Thentestoperatetoseeifthetrouble has beenfixed. (3) Ifseveremachinevibrationisstillpresent,checktoseewhether the variable drive belts are unbalanced. Balance the drive belts, if required,thentestoperatetoensurethatthemalfunctionnolongerexists. c. Troubleshooting the Malfunction: SEVERE SAW BAND VIBRATION DURING SAWING. When severe saw band vibration occurs during sawing operations, makethesechecks: (1) Check the band speed. Saw band vibration can be caused by the selectionoftheincorrectbandspeed. (2) If the band speed is correct, the pitch of the saw blade may be incorrect. Check the pitch of the saw blade, and select a blade of the properpitch. (3) If a blade with the proper pitch is in use, but severe saw band vibrationisstillpresent,thechoiceofcoolantmaybeincorrect.Select thepropercoolanttosolvethisproblem. (4) Ifthecoolantbeingusediscorrect,itispossiblethatthefeed pressureisincorrect.Varythefeedpressuretoseeifthisiscausingthe trouble. (5) Severesawbandvibrationcanoccuriftheworkpieceisnotfirmly clampedtothetable.Ifthisisthecase,adjusttheclampstosolvethe problem. (6) Worn or improperly adjusted saw guide inserts can cause saw band vibration.Adjustorreplacethesawguideinserts,asrequired. (7) Awornsawguidebackupbearingcouldbecausingtheproblem.Check thesawguidebackupbearingandreplaceit,ifneeded.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (8) Whentheheavyworkslideortheheavyworkclampisused,special supportmustbeusedundertheworkpiece. Ifspecialsupportisnotused, sawbandvibrationcouldresult. d. Troubleshooting the Malfunction: TRANSMISSION WILL NOT STAY IN GEAR. Ifthetransmissionwillnotstayingear,themostprobablecauseisworn gears. The machine should be returned to the factory for transmission repairs. e. Troubleshooting the Malfunction: TRANSMISSION WILL NOT SHIFT INTO GEAR. Threeconditionscouldcausethetransmissiontofailtoshiftinto gear. (1) It is possible that the transmission will not shift into gear becausethereisaloosesetscreworbrokenrollpinsintheshiftlinkage. Checktheshiftlinkageforaloosenedsetscrewandforbrokenrollpinsand repair,asneeded. (2) Ifthecomponentsoftheshiftlinkagearenotcausingtheproblem, theshiftmechanisminthetransmissionmaybejammed.Ifthisisthecase, themachineshouldbereturnedtothefactoryforservice. (3) The sliding clutch jaws in the transmission may be jammed or damaged,causingthetransmissiontofailtoshiftintogear.Whenthisis thecase,themachineshouldbereturnedtothefactoryforservice. f. Troubleshooting the Malfunction: SAW BAND IS CUTTING INACCURATELY. Whenthesawbandiscuttinginaccurately,anumberofchecksshouldbemade tofindthecauseofthetrouble. (1) First,checkforwornbladeteeth. Replacethebladeiftheteeth areworn.Thentestoperatetoseeiftheproblemhasbeensolved. (2) Ifthescaleontheworkpiecehasnotbeenremoved,inaccuratecuts willresult.Removethescalefromtheworkpiece,ifneeded. (3) Theworkpiecemayhavebecomehardenedbythegrindingperformedto removethescale. (4) Theblademaybetoowidefortheradiusbeingcut.Checktheblade width,andselecttheproperblade,ifnecessary.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (5) The saw band or the insert may be improperly aligned. Make the requiredalignments,andtestoperatetoseeiftheproblemhasbeenfixed. (6) Itispossiblethatinaccuratecutsaretheresultofthepostnot beingsquaretothetable.Correctthisproblembysquaringtheposttothe table. (7) Using the incorrect feedforcecancauseinaccuratecuts. Adjust thefeedforce,asneededtocorrecttheproblem. (8) Inaccuratebandspeedscanalsocauseinaccuratecuts. Adjustthe speed,asneededtosolvetheproblem. (9) If coolant is not applied evenly to both sides of the saw band, inaccurate cuts may result. Check for this condition and correct it, if necessary. (10) Ifthesawguideontheupperpostisnotlocatedcloseenoughto theworkpiece,inaccuratecutsmayresult. Adjustthepositionofthesaw guide,ifneeded. (11) Choosing the incorrect saw band could cause the problem of inaccuratecuts.Selectthecorrectsawband,asrequired. (12) Inaccurate cuts can also result from incorrect saw band tension. MoretensionshouldbeusedforaDartbladethanforacarbonblade.Check thebandtension,andadjustit,asneeded. g. Troubleshooting the Malfunction: SURFACE FINISH ON THE WORK IS TOO ROUGH. Whenthesurfacefinishontheworkpieceistoorough,thenanyof the following conditions could be the cause. Check these conditions and makecorrectionsoradjustments,asneeded: (1) Thesawguideinsertsmaybeworn.Readjustthem,asneeded. (2) Thesawbandspeedmaybetoolow. (3) Thesawbandpitchmaybetoocoarse. (4) Thefeedmaybetooheavy.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (5) Vibrationcouldcausethiscondition.Seeparagraphs3b,beginning onpage67,and3c,beginningonpage68,tosolvevibrationproblems. h. Troubleshooting the Malfunction:SAWBANDTEETHSTRIPPING. Saw band teethstrippingisusuallycausedbychipwelding.Itmayalsobecausedby thefollowing: (1) Thesawbandpitchmaybetoocoarseforathinworksection. (2) Theworkpiecemaynotbeheldfirmlyenoughtostopvibration. (3) Thefeedpressuremaybetoohigh. (4) Thebandspeedmaybetoolow. i. Troubleshooting the Malfunction: PREMATURE SAW BAND BREAKAGE. Prematuresawbandbreakageisusuallycausedbyteethstripping. Itmay alsobecausedbythefollowingconditions: (1) Thesawbandspeedmaybetoolow. Adjustthespeedasneededto correcttheproblem. (2) Thefeedingforcemaybetoohigh.Adjustthefeed,asrequired. (3) The pitch of the saw band may be too coarse. Use a finer pitch band. j. TroubleshootingtheMalfunction:PREMATUREDULLINGOFSAWBANDTEETH. Premature dulling of the saw band teeth may be caused by any of these conditions: (1) The saw band must be broken in on the first few cuts by using a reducedfeedpressureandspeed.Ifthesawbandisnotbrokenin,dulling ofthesawbandteethcanoccur. (2) Thebandspeedmaybetoohigh,causingabrasion.Reducethespeed, asneeded. (3) Thesawbandpitchmaybetoocoarse. Chooseabandwithafiner pitch. (4) Prematuredullingofthesawbandteethcanoccurifthewrongtype ofcoolantisused,orifnocoolantisused.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (5) Thefeedpressuremaybetoolight. Increasethefeedpressureas requiredtosolvetheproblem. (6) Thecoolantmaynotbecoveringthesawband.Makeadjustments,as needed. (7) Thecuttingratemaybetoohigh. (8) The material being cut may be faulty, having a heavy scale, inclusions,hardspots,etc. (9) Thematerialanalysismaybeincorrect. (10) Sawbandvibrationcancauseprematuredullingoftheblade. (11) If achipped tooth islodgedinthecut,thesawbladewilldull prematurely. (12) Chipweldingcanalsocauseprematuredullingoftheblade. (13) Iftheinsertsaretoolargeforthebladewidth,theinsertsmay hitthesetteeth,causingthebladetodullprematurely. k. Troubleshooting the Malfunction: MOTOR RUNS BUT THE BAND DOES NOT MOVE. Several conditions could cause the band to remain stationary even whenthemotorisrunning. (1) The drive belts could be broken, or they may be off the pulleys. Replaceoradjustthebelts,asneeded. (2) Overoilingofthevariablepulleymayhavecoatedthepulley(and subsequentlythebelts)withoil,causingthebeltstoslip. (3) Thedrivebelttensionmaybetoolow. Adjustthetensiononthe drivebelt,asneeded. (4) Usingthewrongsizeofdrivebeltcanalsocausethisproblem. (5) Ifthebandtensionisincorrect,themotorcouldrunwhiletheband remainedstationary. l. Troubleshooting the Malfunction: BAND SLIPS OFF THE WHEELS. Three conditionscouldcausethebandtoslipoffthewheels:

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (1) Theupperwheelmaynotbealignedcorrectly,sothatthebanddoes nottrackonthecenterofthewheeltire.Adjustthetrackoftheband,as required. (2) Toomuchcoolantorthewrongtypeofcoolantcancausethebandto slipoffthewheeltires. (3) Theinitialmachinealignmentmaybewrong.Whenthisisthecase, refer to TM 9341922710, page 3 for the procedure needed to solve the problem. m. Troubleshooting the Malfunction: EXCESSIVE INSERT AND BLADE WEAR. Whenthereisexcessiveinsertandbladewear,makethesechecks: (1) Check to see if the inserts are adjusted too tight on the blade. Makeadjustmentsasneeded. (2) Checktoensurethatthebandisbeinglubricatedproperly. High bandspeedcausesfriction.Coolantshouldbeusedtolubricatetheband. (3) Checktoseeiftherollersontherollerguidesareadjustedtoo tightontheblade.Loosentherollerguides,ifneeded. (4) The chip brush may be worn, or may not be adjusted properly, allowingthechipstostayonthewheel.Checkforthiscondition,andmake thenecessaryrepairs. n. TroubleshootingtheMalfunction:FILEBANDBREAKS.Whenthefileband breaks,twoconditionscouldbethecause: (1) Thefeedforcemaybetoohigh.Adjustthefeedforcetosolvethe problem. (2) Thewrongtypeoffilebandmaybeinuse. Makesurethatafile bandofthepropershape,width,andnumberofteethisbeingusedforthe materialintheworkpiece. o. TroubleshootingWhenThereisaPOORFINISHFROMBANDFILING.Apoor finish from band filing could be the result of any of the following conditions:

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (1) Thefeedforcecouldbetoohigh.Reducethefeedforce,asneeded. (2) Thefilebandmaynotbeassembledcorrectly. (3) The band tension may be too high. Set the band tension at the settingusedfora1/8inchwidecarbonband. p. Troubleshooting the Malfunction: FILE BAND TEETH BECOME LOADED. If thebandteethbecomeloaded,cleantheteethimmediatelyandthencheckfor theseconditions: (1) Thefeedforcemaybetoohigh.Adjustthefeed,asneeded. (2) Itmaybethatnocoolantisbeingused.Usecoolanttoimprovethe finish. (3) The wrong shape of file may be in use, or the file may have the wrongnumberofteethforthematerialoftheworkpiece. q. TroubleshootingWhenThereisNOCOOLANTFLOW.Ifthereisnocoolant flow, check for the presence of one of these conditions and remedy the situation,asrequired: (1) Checktoseeifthecoolantapplicatornozzleisjammed. (2) Checktoseeifthecoolanthoseiscloggedorkinked. (3) Checktoseeifthecoolantreservoirisempty. 4. TroubleshootingFaultSymptomsintheModel26121MBandsawMachine

Themalfunctionsymptoms,togetherwiththeirpossiblecauses,forthemodel 26121Mbandsawmachinearesimilartothosedescribedforthemodel16120 machine. As stated earlier, theremediesforthesepossiblemalfunctions will notbediscussedindetailhere. Operationalsolutionstoproblems, such as adjusting the speed controls, can be found in TM 9341922810, pages4through20.Lubricationinstructionsandmaintenancesolutionsfor malfunctions,suchasadjustingthe

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 drivebelts,canbefoundinTM9341922810,onpages21through25.This TM should always be referred to when actual repair or troubleshooting proceduresareperformed. a. Troubleshooting the Malfunction: MACHINE WILL NOT START. When the model 26121M bandsaw machine will not start, three conditions couldbe causing the problem. To locate the source of the trouble, make these checks. (1) First,checkthemainfusesandthecontrolcircuitfuse. Replace anyfusethatisdefective.Ifafuseisreplaced,trytostartthemachine toseeiftheproblemisstillpresent. (2) If all the fuses are good but the machine will still not start, check the reset on the band drive motor starter (if a starter is used). Startingandstoppingthemachineanumberoftimesinquicksuccession,or an overload,willtripthestarterheater. Afterlocatingandcorrecting thetrouble,pushintheresetbutton. (3) Ifthemachinewillstillnotstart,checkthetransformer.Replace thetransformerifnecessary. Testoperatetoensurethattheproblemhas beeneliminated. b. TroubleshootingtheMalfunction:MACHINEVIBRATION.Machinevibration maybetheresultofthepresenceofeitheroftwoconditions. (1) The band wheels may have become unbalanced. Check to see if the bandwheelsarebalanced. (2) Ifthebandwheelsarebalanced,andvibrationisstillpresent,it ispossiblethatthedrivebeltsmayhavebeenreplacedbybeltswhichare unbalanced. Balance the drive belts, as required, then test operate to ensurethatthemalfunctionnolongerexists. c. Troubleshooting the Malfunction: SAW BAND VIBRATION DURING SAWING. Whensawbandvibrationoccursduringsawingoperations,makethesechecks: (1) Checkthebandspeedandthefeedforce.Sawbandvibrationcanbe causedbytheselectionoftheincorrectbandspeedorbytheincorrectfeed pressure.Makeadjustmentsasneededtocorrecttheproblem.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (2) Ifthebandspeedandfeedarecorrect,thepitchofthesawblade maybeincorrect.Checkthepitchofthesawblade,andselectabladeof theproperpitch,ifrequired. (3) Sawbandvibrationcanoccuriftheworkpieceisnotfirmlyclamped tothetable.Ifthisisthecase,adjusttheclampstosolvetheproblem. (4) Worn or improperly adjusted saw guide inserts can cause saw band vibration.Adjustorreplacethesawguideinserts,asrequired. (5) Awornsawguidebackupbearingcouldbecausingtheproblem.Check thesawguidebackupbearingandreplaceit,whenneeded. d. Troubleshooting the Malfunction: SAW BAND IS CUTTING INACCURATELY. Whenthesawbandiscuttinginaccurately,anumberofconditionscouldbe responsibleforthetrouble. (1) First,checkforwornbladeteeth. Replacethebladeiftheteeth areworn.Thentestoperatetoseeiftheproblemhasbeensolved. (2) Ifthescaleontheworkpiecehasnotbeenremoved,inaccuratecuts willresult.Removethescalefromtheworkpiece,ifneeded. (3) Thebladeinusemaybetoowidefortheradiusbeingcut. Check thebladewidth,andselectamoreappropriateblade,ifnecessary. (4) The saw band or the insert may be improperly aligned. Make the neededalignments,andtestoperatetoseeiftheproblemhasbeenfixed. (5) Using either the incorrectfeedforceortheincorrectband speed cancauseinaccuratecuts.Adjustthefeedforceand/orthebandspeed,as needed,tocorrecttheproblem. (6) If coolant is not applied evenly to both sides of the saw band, inaccurate cuts may result. Check for this condition and correct it, if necessary.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (7) Ifthesawguideontheupperpostisnotlocatedcloseenoughto theworkpiece,inaccuratecutsmayresult. Adjustthepositionofthesaw guide,ifneeded. (8) Inaccurate cuts can also result from incorrect saw band tension. Checkthebandtensionandadjustit,asneeded. e. Troubleshooting the Malfunction: EXCESSIVE INSERT AND BLADE WEAR. Whenthereisexcessiveinsertandbladewear,makethesechecks: (1) Checktoseeiftheinsertsareadjustedtootightlyontheblade. Makeanyneededadjustments. (2) The chip brush may be worn, or may not be adjusted properly, allowingthechipstostayonthewheel.Checkforthiscondition,andmake thenecessaryrepairs. f. TroubleshootingtheMalfunction:FILEBANDBREAKS.Whenthefileband breaks,twoconditionscouldbethecause: (1) Thefeedforcemaybetoohigh.Adjustthefeedforcetosolvethe problem. (2) Thewrongtypeoffilebandmaybeinuse.Makesurethatthefile bandmeetsalltherequirementsforfilingthematerialintheworkpiece. g. TroubleshootingWhenThereisaPOORFINISHFROMBANDFILING.Apoor finish from band filing could be the result of any of the following conditions: (1) Thefeedforcecouldbetoohigh.Reducethefeedforce,asneeded. (2) Thefilebandmaynotbeassembledcorrectly. (3) The band tension may be too high. Set the band tension at the settingusedfora1/8inchwidecarbonband. h. Troubleshooting When the SURFACE FINISH ON THE WORK IS TOO ROUGH. When the surface finish on the workpiece is too rough, any of following couldbethecause.Checkforthepresenceofoneofthese

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 fiveconditions,andmakecorrectionsoradjustments,asneeded: (1) Thesawguideinsertsmaybeworn.Readjustthem,asneeded. (2) Thesawbandspeedmaybetoolow. (3) Thesawbandpitchmaybetoocoarse. (4) Thefeedmaybetooheavy. (5) Vibration could cause this condition. The troubleshooting procedures usedtosolvevibrationproblemscanbefoundinparagraphs4b and4c,beginningonpage75. i. TroubleshootingtheMalfunction:PREMATUREDULLINGOFSAWBANDTEETH. Premature dulling of the saw band teeth may be caused by any of these conditions: (1) The saw band must be broken in on the first few cuts by using a reducedfeedpressureandspeed.Ifthesawbandisnotbrokeninthisway, prematuredullingofthesawbandteethcanoccur. (2) Thebandspeedmaybetoohighcausingabrasion.Reducethespeed, asneeded. (3) Thesawbandpitchmaybetoocoarse. Chooseabandwithafiner pitch. (4) Thefeedpressuremaybetoolight. Increasethefeedpressureas neededtosolvetheproblem. (5) Thecoolantmaynotbecoveringthesawband.Makeadjustments,as needed. (6) Thecuttingratemaybetoohigh. (7) There may be a fault in the material being cut, such as a heavy scale,inclusions,orhardspots. (8) Saw band vibration can cause premature dulling of the blade. Troubleshootingprocedurestosolvesawbandvibrationproblemscanbefound inparagraph4c,beginningonpage75.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (9) If achipped tooth islodgedinthecut,thesawbladewilldull prematurely. (10) Chipweldingcanalsocauseprematuredullingoftheblade. (11) Iftheinsertsaretoolargeforthebladewidth,theinsertsmay hitthesetteeth,causingthebladetodullprematurely. j. Troubleshooting the Malfunction: BAND SLIPS OFF THE WHEELS. Two conditionscouldcausethebandtoslipoffthewheels: (1) Theupperwheelmaynotbealignedcorrectly,sothatthebanddoes nottrackonthecenterofthewheeltire.Adjustthetrackoftheband,if needed,sothatittracksonthecenterofthewheeltire. (2) Theinitialmachinealignmentmaybewrong.Whenthisisthecase, refer to TM 9341922810, page 2, for the procedure needed to solve the problem. 5. TroubleshootingFaultSymptomsintheModel26141BandsawMachine

Fault symptomsandtheirpossiblecausesforproblemsinthemodel26141 bandsaw machine are described below. As stated earlier, the specific repairs needed to eliminate these malfunctions will not be discussed in detailhere. Operationalsolutionstoproblems,suchasadjustingthesaw guides,canbefoundinTM9340521014&P,pages5through15.Lubrication and maintenance solutions for malfunctionscanbefoundinTM93405210 14&P,onpages15through18.ThisTMshouldalwaysbeusedasareference whenactualrepairortroubleshootingproceduresareperformed. a. Troubleshooting the Malfunction: MACHINE WILL NOT START. When the model 26141 bandsaw machine will not start, make these three checks to isolatethecauseoftheproblem: (1) First,checkthemainfusesandthecontrolcircuitfuse.Anyfuse thatisdefectiveshouldbereplaced.Ifafuseisreplaced,trytostart themachinetoseeiftheproblemhasbeensolved.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (2) Ifallthefusesareoperational,butthemachinewillnotstart, check the reset on the band drive motor starter (if a starter is used). Startingandstoppingthemachineanumberoftimesinquicksuccession,or an overload,willtripthestarterheater. Afterlocatingandcorrecting thetrouble,pushintheresetbutton.Iftheheaterrelayhasbeensetfor automaticoperation,itwillnotbenecessarytopushtheresetbutton,but willonlybenecessarytowaitfortherelaytocool.Thentrystartingthe machinetoseeifthemalfunctionisstillpresent. (3) If the malfunction is still present, check the transformer, and replaceit,ifnecessary.Testoperatetoensurethattheproblemhasbeen fixed. b. Troubleshooting the Malfunction: SEVERE MACHINE VIBRATION. Three conditionscouldcauseseveremachinevibration. (1) Ifthebandwheelsarenotbalanced,machinevibrationcouldresult. Checktoseeifthebandwheelsarebalanced. (2) If the band wheels are balanced, and vibration is still present, checktoseeifthevariablepulleycomponentsarebalanced. Iftheyare not balanced, vibrations could result. Balance the components of the variable pulley, if needed. Thentestoperatetoseeifthetrouble has beenfixed. (3) Ifseveremachinevibrationisstillpresent,checktoseewhether the variable drive belts are unbalanced. Balance the drive belts, if required, then test operate to ensure that the malfunction is no longer present. (4) Severe machine vibrationcanresultifthebandsawmachineisnot resting evenly on the floor. To correct this condition, refer to the alignmentprocedureinTM9340521014&P,page1. c. Troubleshooting the Malfunction: SAW BAND VIBRATION DURING SAWING. Whensawbandvibrationoccursduringsawingoperations,makethesechecks: (1) Check the band speed. Saw band vibration can be caused by the selectionoftheincorrect

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 bandspeed.Adjustthebandspeed,asneededtocorrectthetrouble. (2) If the band speed is correct, the pitch of the saw blade may be incorrect. Check the pitch of the saw blade, and select a blade of the properpitch,ifrequired. (3) Ifabladewiththeproperpitchisinuse,butsawbandvibration isstillpresent,thechoiceofcoolantmaybeincorrect.Selecttheproper coolanttosolvethisproblem. (4) Ifthecoolantbeingusediscorrect,itispossiblethatthefeed pressureisincorrect.Varythefeedpressuretoseeifthisiscausingthe trouble. (5) Severesawbandvibrationcanoccuriftheworkpieceisnotfirmly clampedtothetable.Ifthisisthecase,adjusttheclampstosolvethe problem. (6) Worn or improperly adjusted saw guide inserts can cause saw band vibration.Adjustorreplacethesawguideinserts,asrequired. (7) Awornsawguidebackupbearingcouldbecausingtheproblem.Check thesawguidebackupbearingandreplaceitwhenneeded. (8) Whentheheavyworkslideortheheavyworkclampisused,special supportmustbeusedundertheworkpiece. Ifspecialsupportisnotused, sawbandvibrationcouldresult. d. TroubleshootingWhenThereisNOCOOLANTFLOW.Ifthereisnocoolant flow, check for the presence of one of these conditions and remedy the situationasrequired: (1) Checktoseeifthecoolantapplicatornozzleisjammed. (2) Checktoseeifthecoolanthoseiscloggedorkinked. (3) Checktoseeifthecoolantreservoirisempty. e. Troubleshooting When the SURFACE FINISH ON THE WORK IS TOO ROUGH. Whenthesurfacefinishonthe

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 workpieceistoorough,thenanyofthefollowingconditionscouldbethe cause.Checkforthesefiveconditions,andmakecorrectionsoradjustments asneeded: (1) Thesawguideinsertsmaybeworn.Readjustthem,asneeded. (2) Thesawbandspeedmaybetoolow.Adjustthebandspeedasneeded toeliminatetheproblem. (3) The saw band pitch may be too coarse. Choose a saw band with a finerpitch. (4) Thefeedmaybetooheavy.Adjustthefeedasrequiredtoeliminate theproblem. (5) Vibration could cause this condition. See paragraphs 5b and 5c, beginning on page 80, for the troubleshooting steps performed to solve vibrationproblems. f. Troubleshooting the Malfunction:SAWBANDTEETHSTRIPPING. Saw band teethstrippingisusuallycausedbychipwelding.Itmayalsobecausedby thefollowing: (1) Thesawbandpitchmaybetoocoarseforathinworksection. (2) Theworkpiecemaynotbeheldfirmlyenoughtostopvibration. (3) The feed pressure may be too high. Adjust the feed pressure as neededtoeliminatethesymptom. (4) The band speed may be toolow. Raisethebandspeedslightlyto eliminatetheproblem. g. TroubleshootingtheMalfunction:PREMATUREDULLINGOFSAWBANDTEETH. Premature dulling of the saw band teeth may be caused by any one of the followingconditions: (1) Thesawbandmustbebrokeninonthefirstfewcuts,orpremature dullingofthesawbandteethcouldoccur.Breakinthesawbandbyusinga reducedfeedpressureandspeedonthefirstcuts.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (2) Thebandspeedmaybetoohigh,causingabrasion. Reducethesaw bandspeedasneeded. (3) Thesawbandpitchmaybetoocoarse. Chooseabandwithafiner pitch. (4) Prematuredullingofthesawbandteethcanoccurifthewrongtype ofcoolantisused,orifnocoolantisused. (5) Thefeedpressuremaybetoolight.Increasethefeedpressure,as requiredtoeliminatetheproblem. (6) Thecoolantmaynotbecoveringthesawband. Makeadjustmentsas needed. (7) Thecuttingratemaybetoohigh. (8) The material being cut may have faults, such as a heavy scale, inclusions,orhardspots. (9) Thematerialanalysismaybeincorrect. (10) Saw band vibration can cause premature dulling of the blade. To eliminate saw band vibration, perform the troubleshooting steps listed in paragraph5c,startingonpage80. (11) If achipped tooth islodgedinthecut,thesawbladewilldull prematurely. (12) Chipweldingcanalsocauseprematuredullingoftheblade. (13) Iftheinsertsaretoolargeforthebladewidth,theinsertsmay hitthesetteeth,causingthebladetodullprematurely. h. Troubleshooting the Malfunction: MOTOR RUNS BUT THE BAND DOES NOT MOVE. Several conditions could cause the band to remain stationary even whenthemotorisrunning. (1) The drive belts could be broken, or they may be off the pulleys. Replaceoradjustthebeltsasneeded. (2) Toomuchoilingofthevariablepulleymayhavecausedthepulley (and subsequently the belts) to be coated with oil, causing the belts to slip.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/TASK 2 (3) Thedrivebelttensionmaybetoolow. Adjustthetensiononthe drivebelt,asneeded. (4) Usingthewrongsizeofdrivebeltcanalsocausethisproblem. (5) Ifthebandtensionisincorrect,themotorcouldrunwhiletheband remainedstationary. (6) It is also possible that the transmission could be bad. It is recommended that a faulty transmission be returned to the factory for repairs. i. Troubleshooting the Malfunction: BAND SLIPS OFF THE WHEELS. Three conditionscouldcausethebandtoslipoffthewheels: (1) Theupperwheelmaynotbealignedcorrectly,sothatthebandwill not track on the center of the wheel tire. Adjust the wheel tilt, if needed,sothatthebandtracksinthecenterofthewheeltire. (2) Toomuchcoolantorthewrongtypeofcoolantcancausethebandto slipoffthewheeltires. (3) Theinitialmachinealignmentmaybewrong.Whenthisisthecase, refertoTM9340521014&P,page1fortheprocedureneededtosolvethe problem. 6. Conclusion

The procedures for troubleshooting malfunctions in the three models of bandsaw machines described in this subcourse are similar. This task has introducedyoutotheseprocedures.RememberthattheappropriateTMshould alwaysbeusedasareferencewhenactuallyperformingthetroubleshooting proceduresonthebandsawmachine.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/PE 2 PRACTICALEXERCISE2 1. Instructions Readthescenarioandrespondtotherequirementsthatfollowthescenario. 2. Scenario You are now fairly confident that the Saudi representative knows enough about bandsaw operation. However, you need to be sure that the bandsaw machines can be maintained properly, and that the Saudi personnel can performtroubleshootingonthemachines,shouldproblemsarise. 3. FirstRequirement Many of the maintenance procedures for the various models of bandsaw machinesaresimilar,orthesameforallmodels.Someprocedures,however, arespecifictoonlyonemodel. Youhavepreparedanoutlinecoveringthe maintenance procedures which apply to the models of the bandsaw machine available to the Saudis. Each question below is based on that outline. Answereachquestioncorrectly. a. Whatmustbedoneifawheelbrushiswornsothatitisnotlonger contactingthewheelface? b. Whattypeoflubricantshouldbeusedonthewheelbearings?

c. What could result if the faces of the variable speed pulley are scored? d. Howisthecentersheaveofthevariablespeedpulleylubricated?

e. Brieflydescribetheprocedureforreplacingawheeltireonthemodel 26121Mbandsawmachine. f. What is used to lubricate the air pump on the model 16120 bandsaw machine? g. Describethepositionofthemotorbracketonthemodel16120bandsaw machinewhenthebracketisproperlyadjusted.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/PE 2 4. SecondRequirement

TheSaudirepresentativehashadhispeopleoperatingthebandsawmachines for practice. They have encountered some problems. This provides an excellent opportunity to introduce some of the procedures for troubleshooting. a. One operator has had problems operating the model 16120 bandsaw machine. The saw band keeps vibrating during the sawing operations. Describe the procedures that should be used to troubleshoot for this symptom. b. Anotheroperatorhasbeenworkingonthemodel26141bandsawmachine. The band keeps slipping off the wheels. Describe the procedure used to isolatethecauseofthisproblem.

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BANDSAW OPERATIONS - OD1646 - LESSON 2/PE 2 LESSON2.PRACTICALEXERCISEANSWERS 1. FirstRequirement a. Loosentheadjustingscrewsandmovethebrushuptothewheel. b. None.Thewheelbearingsaresealedandlubricatedforlife. c. Thebeltscouldbedamaged. d. Thecentersheaveofthevariablespeedpulleyislubricatedbyawick whichisimmersedinoil. e. Toreplaceawheeltireonthemodel26121Mbandsawmachine,remove thetworetainersfromthefrontofthebandwheel. Thenremovethetire retaining rings. Drive the tire off the wheel, sawing off the steel backing, if necessary. Mount a new tire so that the two notches in the steel backing are in alignment withthetwotireretainers. Putthe new tireonwithlighttapsofasoftfacedhammer,rotatingthewheelabout30 degrees aseachtapismade, untilthetireisagainsttheflangeof the wheel. f. Powderedgraphiteisusedverysparinglytolubricatetheairpump. g. Thebracket,whenproperlyadjusted,willjustclearthemotorplate whenitisatitshighestpositionduringoperation. 2. SecondRequirement a. Whensawbandvibrationoccursduringsawingoperationsonthemodel 16120bandsawmachine,thesechecksshouldbemade: (1) Check the band speed. Saw band vibration can be caused by the selectionoftheincorrectbandspeed. (2) If the band speed is correct, the pitch of the saw blade may be incorrect. Check the pitch of the saw blade, and select a blade of the properpitch,ifrequired. (3) If a blade with the proper pitch is in use, but severe saw band vibrationisstillpresent,the

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BANDSAW OPERATIONS - OD1646 - LESSON 2/PE 2 choiceofcoolantmaybeincorrect.Selectthepropercoolanttosolvethis problem. (4) Ifthecoolantbeingusediscorrect,itispossiblethatthefeed pressureisincorrect.Varythefeedpressuretoseeifthisiscausingthe trouble. (5) Severesawbandvibrationcanoccuriftheworkpieceisnotfirmly clampedtothetable.Ifthisisthecase,adjusttheclampstosolvethe problem. (6) Worn or improperly adjusted saw guide inserts can cause saw band vibration.Adjustorreplacethesawguideinserts,asrequired. (7) Awornsawguidebackupbearingcouldbecausingtheproblem.Check thesawguidebackupbearingandreplaceit,whenneeded. (8) Whentheheavyworkslideortheheavyworkclampisused,special supportmustbeusedundertheworkpiece. Ifspecialsupportisnotused, sawbandvibrationcouldresult. b. Three conditions could causethebandtoslipoff thewheels on the model26141bandsawmachine: (1) Theupperwheelmaynotbealignedcorrectly,sothatthebandwill not track on the center of the wheel tire. Adjust the wheel tilt, if needed,sothatthebandtracksinthecenterofthewheeltire. (2) Toomuchcoolantorthewrongtypeofcoolantcancausethebandto slipoffthewheeltires. (3) Theinitialmachinealignmentmaybewrong.Whenthisisthecase, refertoTM9340521014&P,page1fortheprocedureneededtosolvethe problem.

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BANDSAW OPERATIONS - OD1646 - REFERENCES

REFERENCES

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BANDSAW OPERATIONS - OD1646 - REFERENCES REFERENCES Thefollowingdocumentswereusedasresourcematerialsindevelopingthis subcourse: TM9340521014&P TM9341922710 TM9341922810 FM924

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