<p>The band saw cutting is one of the many cutting/machining operations that can benefit from cutting conditions and cutting fluid optimization. Optimizing cutting speed, feed rate, and cutting fluid application based on the cut material can increase the blade's life. Most of the academic and industry work is focused on optimizing the cutting tool design and cutting conditions such as band saw blade speed and feed rate. Most of the band sawing industry uses flood cutting fluid to reduce the cutting temperatures, remove chips, and also (in some cases) act as a lubricant. There is a lack of comprehensive understanding of the role of cutting fluid, and its method of application in the band saw cutting. In this paper, cutting fluid application on the cutting performance metrics such as surface roughness, cut surface waviness, and cut time variation was studied. The study also focuses on the chip formation and cutting forces generated while cutting with and without cutting fluid application. A flood cutting fluid application (recommended for the difficult-cut-material), varying amounts, and compositions of the minimum quantity of cutting fluid applications are studied along with dry (or no cutting fluid application) cutting.&nbsp; The minimum quantity cutting fluid composition is varied to understand the effectiveness of sustainable cutting fluid (water and compressed air). A difficult-to-cut material was used as workpiece material, and a carbide-tipped band saw blade was used as the cutting tool. The cutting conditions, that is, bandsaw blade speed and feed rate, are varied while keeping the depth of cut constant. Depth of cut or (in case of the band saw cutting process) chip load was measured using the cutting speed and the feed rate. In general, the band saw teeth split the kerf to improve the cutting process through reduced cutting temperatures and forces. The cutting conditions influence the chip formation and kerf splitting process. The study results show that the sustainable cutting fluid application, that is, the minimum quantity fluid improves the cutting performance, while the cutting forces required were increased. The results concluded that a cutting fluid application is required for cutting difficult-to-cut materials, and its method of application affects the band saw blade life. The results show that minimum quantity cutting fluid efficacy was affected by the composition of the cutting fluid. Thus this work provides the user with a road map in selecting cutting fluid and application parameters based upon cutting requirements. This road map can be used to improve the band saw blade life, improve the cut-surface roughness.</p>

Cutting Fluid Application for Bandsawing: A Sustainable Solution for Cutting Solids

Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2021/volume/85543

ASME 2021 International Mechanical Engineering Congress and Exposition (IMECE2021)

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