CHAPTER FOUR

4.0 Introduction

The band saw machine is a versatile power tool that is used for cutting various materials, such as

wood, metals, and plastic. It consists of a continuous band of toothed metal, called a blade,

stretched between two or more wheels. The horizontal band saws are primarily used for cutting

metal stocks, such as angle irons and other round flat stock with ease. The blade runs

horizontally on two pulleys through two separate guides. The operator secures the stock on the

table and manually assists the saw as its cuts.

However, the process involved in the operation of the band saw machine is as follows;

 Preparation: Begin by properly setting up and securing the workpiece on the worktable or

vise of the band saw machine. This ensures stability and safety during the cutting.

 Selection of blade and speed, choose an appropriate blade for the material being cut.

Blade may vary in size, tooth pattern and material composition .Set the cutting speed

according to the material hardness and desired cutting efficiency.

 Adjustments: Make necessary adjustments to the blade tension and tracking mechanisms

of the band saw machine. Proper tension ensures accurate cutting and prevents blade

breakage while tracking adjustments keep the blade centered on the machine wheel.

 Power on the machine: Turn on the power supply to activate the machine.

 Cutting process: Feed the workpiece slowly and steadily into the blade, controlling the

feed smooth and precise cutting. Ensure that the blade is positioned properly, aligned

with the marking lines on the workpiece or following any cutting guides if necessary.
  Monitoring and control: Observe the cutting process carefully while steadily clear of the

blade. Important factors to monitor incudes, the cutting progress, blade condition and

overall machine performance. Make any necessary adjustments during the cutting process

to ensure optimal results.

 Completing: Once the desired cut is made, power off the machine to come to complete

stop before removing the workpiece.

 Post- cutting tasks: Inspect the cut surface for accuracy and smoothness. Remove any

debris or chips that may accumulated during the cutting process. Additionally, perform

regular maintenance on the machine such as blade cleaning and lubrication to ensure it

longevity and continued performance.

4.1 Operational Safety

Personal safety is a concept that we all need to have in order to feel safe when running your daily

lives. In the engineering field, this helps to guide the operator and bystanders from accidents,

injuries and losses.

The following personal safety should be observed when using the band saw machine is as

follows;

 Wear safety glasses and goggles or face shield fitted with transparent glass when using

the machine.

 Wear hearing protection that is suitable for the level of frequency of the noise you are

exposed to in the working area.

 Wear protective footwear when using the machine.

 Make sure all guards are in place and properly adjusted.

  Make sure the blade is in good condition.

 Ensure the blade is positioned properly on the frame.

 Adjust the blade guard height to about 3mm to 6mm above the top of the material being

cut. Wider gap will place tension on the blade and increase the risks of breaking.

 Ensure that the bade is under proper tension.

 Use band saw blade that is sharp, properly set and other wise suitable for the job (the

right tooth pitch, tooth form and blade width).

 Keep hands away from the line of cut and braced against the table.

Things to avoid when operating a band saw machine, they includes the following;

 Do not leave the saw running unattended. Turn off the power and make the sure the

machine has stopped running before leaving the working area.

 Do not remove the metal particles from the table by hands, use a brush.

 Never try to hold the work in position by using your hands, use the vise.

4.2 Kind of Operations.

The horizontal band saw utilize a thin metal ribbon like loop with hardened teeth moving in a

generally horizontal plane to cut metallic objects .The moving blade sweeps an arc thru a fixed

cutting plane to produce repeatable fixed angle cuts .Only straight cuts at a fixed can be made on

the horizontal band saw .the horizontal band saws are not equipped for cutting patterns or

intricate curves, but they have excellent precision for straight cut at a fixed angle.

4.3 Materials that can be cut by the band saw machine

The bade comes in a variety of size and tooth pitches which enables the machine highly versatile

and able to cut a wide variety of materials .The blade is made from a specialized alloy steel .The
blade is made by annealing the body of the blade and hardening only the teeth that makes it

suitable for the operation. However, materials that can be cut by the machine (blade) are as

follows; mild steel, copper, wood, plastic, cast iron, brass, lead, bronze, zinc, and non- ferrous

metals.

4.4 Types of Coolants used by the Machine

Coolant is a substance, typically liquid that is used to reduce or regulate the temperature of a

system. An ideal coolant has high thermal capacity, low viscosity, low cost, non- toxic,

chemically inert and neither causes nor promotes corrosion of the cooling system. In most cases,

generic water-based band saw coolant is a cost -effective way to run the band saw with higher

speed and extended blade life. For more specific applications, you can use oil -base coolants,

synthetic coolants. It also reduces the heat from these sources and prevents metal chips from

welding to the tooth face and altering the chip -removal capacity of the band gullets, dramatically

affecting the blade performance.

4.5 Type of Coolant Pump Used

A coolant pump is a type of pump used to recirculate a coolant, generally a liquid, that is used to

transfer heat away from an engine or other devices that generates heat as a byproduct of

producing energy. The SA pump is a motor -driven pump for machine tools. It is suitable for

smaller, primary semi- automatic and manual.

4.6 Limitation of the Band Saw Machine

When it comes metal work and welding and other similar industry, the band saw plays a vital

role because of its versatility, this machine has the ability to create precise intricate cuts in
various materials. While there are many benefits to using the band saw, there are also drawbacks

or limitations to this machine as follows:

Cost

One of the biggest drawbacks of the band saw is its cost, this tool is expensive, especially if one

is looking for a high quality model.

Maintenance

Another limitation is the maintenance, a band saw requires regular maintenance to keep it in

good working order, this can include changing of blade, adjusting the tension and lubricating the

mechanism.

Space

The band saw can take up to a lot of space in the workshop because of it large size, the one in

welding department shop is about 10feet long and can take up to the square of its length when in

operation.

Noise

Band saw can make loud noise which gradually pollute the hearing of the operator when expose

for long term.

4.7 Repair and Maintenance

 Evaluate band wheel bearing and check for abnormal movement.

 Replace hydraulic fuel fitter.

 Inspect and adjust the blade guide.

 Clean the hydraulic fluid reservoir magnetic plug.

 Assess the vises, belts, drives and band guide.

 And finally test ran the machine to make sure that its operation is smooth and cuts

effectively.