Active runout compensation using the guide elements on metal band saws for a longer tool life and reduced material loss

Abstract At a time of rising energy and material costs, manufacturing process efficiency is becoming increasingly important. This is one reason why cutting and especially sawing processes, usually the first step in most manufacturing chains in discrete part production, have to be investigated more intensively. Due to problems with runout and poor surface finishes, raw material is conventionally cut to oversize by either circular sawing or band sawing. This oversize has to be removed by following processes, costing extra energy and wasting material. Since the problem of runout increases with increasing tool wear due to higher deflections of the thin and compliant tools, an even larger oversize is required. This paper describes an approach to reduce the need of oversize even with increasing tool wear in band sawing by tilting the saw band in order to compensate for tool deflections during cutting. To achieve this, it is necessary to measure and understand the saw band runout. The next step is to present a system design and controller for tilting the saw band. Finally, tests are carried out to analyse the effectiveness of the system. In addition, the approach allows the use of increased process parameters to the end of the tool life without losing more material. The tool can therefore be used productively for a longer time period.