Fraunhofer Institute for Manufacturing Engineering and Automation IPA
Band Saw Tools Compared: An Objective Assessment of Quality and Process Stability
In a nutshell
On behalf of Bichamp Cutting Technology EMEA, the Fraunhofer IPA investigated the influence of various bi-metal band saw tools on process stability and cut quality. In a scientific benchmark test, tools from established manufacturers were evaluated under comparable conditions.
In detail
Band sawing is an established industrial cutting process and often the first step in a manufacturing chain. The quality of the cut and the stability of the sawing process can have a direct impact on subsequent machining steps, costs, and material usage.
As part of a benchmark initiated by BICHAMP Cutting Technology EMEA GmbH, the Fraunhofer IPA investigated the influence of various bi-metal band saw tools on the band sawing process. The goal was to evaluate tools from established manufacturers under comparable conditions and to demonstrate their influence on process stability and cut quality using objective, reproducible parameters.
The focus was thus on band saw tools. The scientific question was how to make tool differences visible and comparable using objective, repeatable parameters.
Scientific methodology for objective comparison
From a scientific perspective, it was particularly important to systematically document the tool’s influence on various quality and process parameters. To this end, evaluation criteria were developed, appropriate measurement and sensor technology were employed, and the tools were tested under comparable conditions. The project followed a structured experimental design:
- Definition of the use case: Band sawing of large-cross-section solid material made of C45 quenched and tempered steel and V2A stainless steel using bi-metal band saw tools.
- Definition of eleven evaluation criteria for the tool, process, and cut quality.
- Selection and integration of suitable measurement and sensor technology.
- Selection of several national and international tools from established manufacturers within a comparable performance segment.
- Running in the tools at reduced feed and cutting speeds.
- Conducting 100 test cuts per tool under material-specific cutting and feed parameters, with sensor-based monitoring.
- Evaluation of the measurement results and validation of the evaluation criteria.
Comparable performance level with new insights
The study showed that the defined evaluation criteria are generally suitable for the structured evaluation of band saw tools and their impact on the process.
Across the parameters examined, the tools under investigation achieved an overall comparable level of performance. While individual deviations in certain measured variables were observable, they did not result in a clear tool-specific trend. Taking the respective variances into account, the results as a whole fell within a comparable range.
At the same time, systematic correlations between individual process and quality parameters were identified, which form an important basis for further analysis.
Another project outcome is a machine-independent measurement setup that will allow other band saw machines, materials, and tool concepts to be examined in the future using a comparable principle.
Foundation for the further development of band sawing processes
The benchmark establishes a scientifically sound foundation for objectively evaluating band saw tools under real-world conditions. This provides companies with new insights into the influence of tools on quality and process stability, as well as a robust basis for future optimizations of the band sawing process.
The developed method can be used in the future to:
- examine additional tools and performance segments,
- evaluate the influence of materials and machine designs,
- analyze the relationships between process parameters and tool performance more precisely, and
- identify specific opportunities for optimizing band sawing processes.
The benchmark thus not only provides a comparison of the tools examined but also lays the foundation for further scientific research and the targeted optimization of industrial band-sawing processes.
Insights into the Project
Wear Mark Measurement on the Tool
The figure shows an example of the optical measurement of the wear mark width on a band saw tooth. As a direct measure of the wear condition of the tool teeth, the wear mark width was recorded at defined intervals after 5, 15, 35, 55, 75, and 100 cuts. The measurement was performed in parallel with other offline evaluation criteria.
The width of the wear marks is an established, tool-specific criterion for evaluating tool life, as it directly reflects progressive wear.
Chip Class Evaluation
The figure shows an example of the chips produced during band sawing. To evaluate chip formation, chips were collected at defined intervals and assigned to the respective chip classes based on characteristic features.
Three-dimensional vibration analysis on the saw frame
To continuously analyze process behavior, acceleration data was recorded and evaluated in real time using triaxial sensors. The vibration analysis maps dynamic changes during the sawing process.
Surface roughness on the workpiece
The arithmetic mean roughness value Ra and the average roughness depth Rz were determined at defined measurement positions as quality criteria for the quantitative assessment of cut surface quality. The determined roughness parameters enable an objective evaluation of the resulting surface as well as the influence of the tool and its wear condition on cut quality.
Customer Quote
»A systematic approach and open collaboration. I’m very satisfied!«
Michael Möller (BICHAMP Cutting Technology EMEA GmbH, CEO)
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