Metal saw blade cutting tools

Types of metal saw blade cutting tools

Metal cutting saw blades are grouped into various types and each of them serves a specific purpose when cutting. These blades’ core material, teeth configuration, and purpose are different. Attention to detail on these aspects is critical since the right saw blade will improve efficiency and the quality of the output.

Steel Circular Saw Blades

They are the most common and they have high versatility. Usually, the blades are made of hardened steel. They are used in the metal cutting because they are durable and also resistant to wear.  

Bimetal Blades

Bimetal blades as the name suggests, are made by welding together two metals to make one diverse blade. Usually, the teeth are made of high-speed steel which is welded on a base of flexible spring steel. This combination brings forth a blade that is both tough and flexible. The teeth resist heat and wear while the base absorbs stress. They are mostly used for cutting variety of metals and give very good results.

Carbide Tipped Blades

The carbide tipped saw blades have tips that are made of tungsten carbide for extreme hardness. The base of the blade is made of steel which is designed to give the blade durability and strength. The carbide tips resist wear and tear and also discourage overheating during cuts. They are ideal for cutting hard metals like stainless steel and aluminium.

Diamond Blades

Metal cutting diamond blades are preferred for their precision. Since they contain synthetic diamonds on the edge, they are able to make very fine cuts. These blades are also heat resistant and will not chip easily. Because of this, they are preferred to cut brittle materials like cast iron.

In addition, due to the hardness of the diamonds, these blades maintain their sharpness for a longer period, hence they are good for more high-quality cuts over a longer period.

Grinding Wheels

Though not circular blades, grinding wheels are used in saws and they also fit in the metal cutting category. These wheels are composed of abrasive particles bonded together, giving them the ability to remove material through erosion. Grinding wheels are used to achieve fine finishes on metal surfaces as well as on precise cutting. Their teeth are actually abrasive particles which can cut through very hard materials.

How to Choose metal saw blade cutting tools

Choosing the right saw blades for cutting metal is key to achieve their optimal performance. There are factors to consider when making this decision:

Blade Material

The material used to make the blade has a direct impact on its durability and the quality of the cut. In cutting metal, carbide and bimetal blades are the most suitable because they can withstand the pressure that comes with cutting metal. Carbide tipped blades have very hard tips that can maintain sharpness on rigorous cuts.

Teeth Configuration

The number and shape of teeth on the blade impact the cut’s smoothness and speed. The finer teeth give smooth cuts but require more time to do it. The teeth that are coarser make fast cuts but may not be as smooth. In choosing the right configuration, consider the metal thickness and the desired finish.

Blade Thickness

The thickness of the blade influences its rigidity. Thicker blades are more rigid and will give better cuts on thicker metals. Thin blades are able to flex and this makes them better suited for cutting sheets or soft metals.

Compatibility

When buying, ensure that the bore size of the blade fits the saw. Also, the blade thickness should be compatible with the sawing machines’ fences and motors. In this case, there will be a proper fit and this will avoid the blades from grabbing or burning. There will also be balanced operation and hence increased safety.

Heat Resistance

Metal cutting produces friction, which in turn generates heat. A blade that is resistant to this heat will not warp or lose its edge easily. Bimetal and carbide tipped blades are ideal for high-heat applications due to their superior heat resistance. These blades will provide consistency in performance during prolonged use.

Industry applications of metal saw blade cutting tools

Lumber industries rely heavily on metal cutting blades. They are mainly used to cut through metal machinery, rail systems, and conveyor belts. For example, carbide-tipped blades help create smooth cuts on metal parts used in sawmills. This increases their efficiency and longevity when cutting wood.

These blades are equally important in the automotive industry. Here, they cut metals used in car parts like engines, transaxles, and driveshafts. Diamond blades provide precision cuts in the most intricate areas for better assembly. Casino saw blades provide quick, clean cuts of steel and aluminum for stamping dies, control arms, brake discs, and other automotive repair tools.

These cutting blades are widely used to build and repair structures in the construction industry. They cut rebar for concrete slabs, beams, and columns. Abrasive blades cut metal rules for measuring and laying out work. Circular steel cutting blades cut pipe for plumbing and HVAC installations. They also cut structural steel and aluminum for building frameworks.

The aerospace industry also benefits from these metal blades. Mostly, they are used to cut high-strength alloys and composites for aircraft parts. Due to their extreme precision, diamond blades can be used to cut edge-fusion metals and intricate surfaces on wings, turbines, and landing gear. These saw blades are developed to reduce heat and ensure that the cut is done smoothly without impacting the material's integrity Reducing burrs and polishing time.

These blades are essential in the electronics industry too. They make clean, accurate cuts on thin metal foils and sheets used to make circuit boards. Saw blades cut the metal housings and frames of electronic devices like smartphones and laptops. They also cut wires and connectors.

Metal saw blades are also widely used in machine shops and metal fabrication industries to cut various metals into parts for big projects. For example, metal cutting blades are used to cut blades in metal framed glasses for precision and style. Also, blade wear is minimised to ensure that the cuts give a polished and smooth finish.

Product Specifications and Features of metal saw blade cutting tools

Key Features

• Material Composition: Metal cutting saw blades are composed of hardened steel, high-speed steel, carbide-tipped, bimetal, or diamond edged.
• Tooth Design: Their teeth are configured in various designs suitable for different metal types and thicknesses.
• Blade Diameter: Their diameter usually range from 4 to 14 inches depending on the saw type and application.
• Bore Size: The bore size is the hole at the centre of the blade, which fits onto the saw blade spindle.
• Teeth Per Inch (TPI): Their teeth number per inch determines the cut’s smoothness and speed.
• Coating: Some blades are coated withprotectiveand durable layers like titanium to increase their lifespan.

How to Install

• Power Off the Equipment: Before starting, switch off the saw or the machine the blade will be installed on. This will ensure safety during installation.
• Remove the Old Blade: Loosen the locking mechanism or nut securing the old blade then take it out. Most saws have a spindle lock to help in this process so as to prevent movement of the blades when loosening the lock.
• Select the Correct Blade: Choose the suitable metal saw blade for the project. Consider metal type, thickness, and desired cut finish when choosing the blade. Check that the bore size and diameter are compatible with the equipment.
• Mount the New Blade: Place the new blade onto the saw, ensuring that its teeth are facing the right direction. This will ensure that it rotates correctly.
• Secure the Blade: Tighten the nut or locking mechanism to secure the blade in place.
• Check Alignment: After securing, spin the blade to check its alignment. A misaligned blade will cause vibration and will produce unsafe cuts.
• Power On the Equipment: Once everything is secure and aligned properly, turn on the equipment to begin cutting.

Maintenance and Repair

• Regular Cleaning: After use, remove debris and metal particles from the blade using a soft brush. This will avoid blade wear and keep the teeth sharp. Avoid using water because it will cause corrosion. Instead, use a suitable blade cleaner solution posted on the metal surface.
• Visual Inspection: Check the blade for any signs of wear, such as nicks, chips, or cracks on the teeth. Inspect for rust or corrosion. Any blade with damaged teeth or structural integrity will impact cutting performance. Replace worn blades with new ones.
• Sharpening: Bring sharpening to the professionals who have expertise on how to sharpen metal cutting blades. Use a bench grinder or a specialized sharpening jig to grind the teeth. Set the correct angle for each tooth type when sharpening. Consistent angles will ensure that the cuts are smooth and precise.
• Tooth Repair: Welding new metal onto worn teeth will give them a new edge. Use high-quality welding rods that match the blade material. This will require a skilled welder to ensure that the repair is done properly without introducing weakness into the blade.
• Alignment: Bent blades can be straightened by gently bending them back into shape. Use pliers and apply minimal pressure to avoid further damaging the blade. Proper alignment reduces vibrations and enhances cutting accuracy. Repair deformations immediately before use.
• Proper Storage: Store blades in a dry, cool place free of moisture and direct sunlight. Use blade guards or cases for protection. Proper storage prevents unexpected damage and prolongs blade life.

Q&A

Q. What materials can metal cutting blades cut?

A. A. They are designed to cut various metals including steel, aluminium, brass, and copper. Some blades also cut hard materials like stainless steel, cast iron, and in some blades, bone and carbide tips are incorporated, allowing them to cut even tougher materials like high-carbon steel and titanium.

Q. What are the signs that a metal cutting blade is worn out?

The following are the indications that a metal cutting blade has worn out.

• Decreased Cutting Speed: If there is a noticeable decrease in speed during cuts, it could mean that the blade has worn out.
• Excessive Heat: An overheated blade during cutting is a sign that the teeth are dull. Too much heat also affects the material
• Vibration: Excessive vibrations when cutting are clear indicators of a bent blade.
• Visual Damage: Also, look for cracks, chips, or rust. Any sign of these deteriorations means its performance has been compromised.

Q. How can users increase the lifespan of their metal cutting blades?

• Use Appropriate Blade: Ensure that the blade is suitable for the specific metal being cut. Choosing the right blade for the job minimises excessive wear and tear.
• Coolant Application: Use of coolants reduces heat build-up during cutting. The heat usually wears out the blade quicker when not addressed.
• Regular Maintenance: Regular maintenance practices like cleaning, inspection, and sharpening optimise performance. This prevents unexpected failure of the blade during a project.
• Proper Storage: Proper storage practices protect blades from damage. This ensures that blades remain in good condition when needed.
• Safe Handling: Handle blades carefully to prevent bends or cracks. Careful handling also reduces the chances of accidents.