Instruction Manual: Model SH-2028M
Instruction Manual: Model SH-2028M
Instruction Manual: Model SH-2028M
Instruction Manual
Model SH-2028M
Semi-automatic Horizontal
。
(45 Backward miter cutting)
Manual
Instruction Manual:
SH-2028M Horizontal Bandsaw
Ver. 1-- Date : 12/19/2006
© 1995 by COSEN CO., LTD./ R&D DIVISION.
110 Ching-Fu Street Hsin-Chu 300, Taiwan, R.O.C.
Tel: 886-3-5332143~5 Fax: 886-3-5348324
No part of this publication may be photocopied or otherwise reproduced without the prior written
permission of COSEN CO., LTD.
Printed in Taiwan
SAFETY
SAFETY
1. Know your band saw. Read the operator‘s manual carefully. Learn the operation, application and
limitation. Realize the specific potential hazards peculiar to this band saw.
2. Use recommended accessories. Improper accessories may be hazardous.
3. Wear proper apparel.
4. Keep unnecessary people away.
* Do not overreach or stand on tool.
5. Avoid dangerous environment. Do not use band saw in damp or wet locations. Keep work area
well illuminated.
6. Keep work area clean. Cluttered and slippery floors invite accidents.
7. Remove adjusting keys and wrenches from band saw before turning on power.
8. Avoid accidental starting. Make sure switch is off before plugging in power cord.
9. Do not force band saw. It is safer to operate with the cutting rate for which it was designed.
10. Never hand hold the material with saw in horizontal position. Always use the vise, and clamp
securely.
11. Keep belt guard and wheel covers in place and in working order.
12. When a workpiece is too long or heavy, support it from the floor.
13. Always remember to switch off the machine when the work is completed.
14. Disconnect power cord before adjusting, servicing and changing blade.
15. Check damaged parts. Before further use of the tool, a guard or other parts that is damaged should
be carefully checked. To assure that it will operate properly and perform its intended function.
16. Moving parts should keep in an alignment and binding. Check for breakage, mounting and any
other conditions that may affect its operation. Any damaged part or guard should be properly
repaired or replaced.
17. Use a sharp blade and keep tool clean for best and safest performance.
18. Safety is a combination of operator‘s common sense and alertness at all times when the saw is
functioning.
19. Maintaining the band saw in top condition is essential for safety.
SAFETY RULES
Never wear gloves loose clothing when operating the machine. They may cause danger if they are
caught in a running machine.
Be sure to confirm that the area around the machine is cleared of people and obstacles every time
before starting the machine or operation.
Use a water-soluble cutting fluid on this machine. Oil-based cutting fluids may emit smoke or catch
fire, depending on the condition of their use.
ALARM.DOC
SAFETY-1
SAFETY RULES
Never try to adjust the wire brush on the saw blade or remove chips when the saw blade is running.
It is dangerous if hands or clothing are caught by the running blade.
Never cut carbon or any other material that produces and disperses explosive dust on this machine.
Sparks from motors and other machine parts may ignite and explode the air-borne dust. The machine
needs special measures for cutting explosive materials.
Stop the saw blade before you clean the machine. It is dangerous if hands or clothing are caught by
the running blade.
ALARM.DOC
SAFETY-2
SAFETY RULES
Be sure to prohibit any use of fire in the shop, and install a fire extinguisher or other fire control
device near the machine when cutting titanium, magnesium, or any other material that produces
flammable chips. Never operate the machine unattended when cutting flammable materials.
Use roller tables on both front and rear sides of the machine when cutting the long work. It is
dangerous if the work falls off the machine when the roller tables are not used.
Take preventive measures when cutting thin or short pieces from the work to keep them from falling.
It is dangerous if the cut piece falls.
ALARM.DOC
SAFETY-3
SAFETY RULES
Never start the saw blade unless it has been confirmed that the work is firmly clamped. If the work is
not securely clamped with the vise, pieces will be forced out of the vise during cutting.
Never touch the running saw blade. It is dangerous if your hands or clothing are caught by the
running blade.
Never step or stand on the roller table. It is dangerous if your foot slips on the rollers and you fall.
ALARM.DOC
SAFETY-4
SAFETY RULES
Turn off the shop circuit breaker switch before servicing the machine. Then post a sign to inform
people that the machine is under maintenance.
ALARM.DOC
SAFETY-5
GENERAL INFORMATION
Section 1
SECTION 1
GENERAL INFORMATION
1.1 INTRODUCTION
This semi-automatic band saw is a model more popular than any other model as witnessed in
many countries worldwide. This machine was developed by a group of R&D engineers over a
considerable period of time assuring you of the highest efficiency and performance. Each component
was developed by computer design and analysis. This machine is specifically designed to cut metal
material. Your machine has the following advantages:
• Machinery and each component part can be handled safely.
• Machinery and each component part can be easily moved or operated by the user.
• Machinery and each component part has passed strict testing. (Council Directive on the
approximation of the laws of the Member States relating to Machinery)
This manual contains shipping, handling, unpacking, initial checkout, operation, maintenance
information, etc. It is divided into ten sections. Each section covers a specific aspect of the machine.
This section contains a general description of the machine and other available documentation. We are
going to introduce this smart machine now.
SEC_1.DOC
1-1
GENERAL INFORMATION
Section 1
1.2.1 Specifications
Angle 0。 45。Backward
SEC_1.DOC
1-2
GENERAL INFORMATION
Section 1
The button is going to be locked when you press it. To unlock it, you must pull it. Its
appearance has red color and rubber material for safe operation. We hope you do not press this
button inadvertently or otherwise.
SECTION 1, 2, 3, -------9,
APPENDIX.
The instruction manual is divided into ten sections. Each section contains important information
on how to operate the machine properly. Some of the safety precautions are described at the beginning
of each section. Please read and understand the manual before operating the machine. For other
technical information, please check with the dealer or the manufacturer for further detail.
1.4 DOCUMENTATION
Other than this manual, the manufacturer also provided other related technical documents along
with the machine. Please read through them should there be a need.
1. Electrical layout of the machine. (Chapter 5)
2. Hydraulic system diagram. (Chapter 6)
SEC_1.DOC
1-3
GENERAL SAFETY INSTRUCTIONS
Section 2
SECTION 2
2.1 INTRODUCTION
In designing this machine, many safety measures have been taken to prevent personal injury.
However, there are still some risks remaining despite all the measures adopted. We then put protective
devices at those places. Other than the safety hardware mentioned above, we have also put warning
labels on the machine as a reminder to the user and listed all these risks in the manual. We separate all
these items into three categories, i.e. danger, warning, and cautions. Please read all DANGERS signs
to prevent death or severe injury. Read all WARNINGS to prevent personal injury, and read all
CAUTIONS to prevent equipment damage. This section covers general safety rules. We also provide
some risk analysis and procedures. The specific precautions for each section are described at the
beginning of each subsection in the later sections. We also provide figure 2.1 for your machine at the
end of this section.
SEC_2.DOC
2-1
GENERAL SAFETY INSTRUCTIONS
Section 2
Read all DANGERS to prevent severe personal injury and death
Red and white DANGER labels mean immediate hazards that will result in severe personal
injury or death.
DANGER: Do not operate this machine unless it is completely assembled.
DANGER: Before doing any electrical work, disconnect the electrical power with the Main
Power Disconnect switch.
DANGER: Before working near moving parts, disconnect the electrical power with the
Main Power Disconnect switch.
DANGER: Keep all guards and shields in place before installing or starting up the machine.
DANGER: It is dangerous to operate the machine when the floor is slippery. Keep the floor
clean and dry. Check for ice, moisture, or grease before entering.
DANGER: Do not use the machine to cut explosive material or high pressure vessels. Since
it will generate high heat during the sawing process that will ignite an explosion.
Orange and black WARNING labels mean hazards or unsafe practices can result in severe
personal injury or death.
WARNING: This manual has important safety information. All users must read it before
performing any activity on the machine, such as replacing the saw band or
doing regular maintenance.
WARNING: Some personal protective equipment is required for the safe use of the
machine, e.g. protection goggles.
SEC_2.DOC
2-2
GENERAL SAFETY INSTRUCTIONS
Section 2
Read all NOTICES to prevent equipment damage
Blue and White NOTICE labels mean unsafe practices that could result in damage to products
or property.
NOTICE: The transmission fluid of the speed reducer needs to be replaced.
Green and white SAFETY INSTRUCTIONS are important reminders that should be read
before operating the machine.
Please do not make any decisions casually without first reading all safety
instructions.
SEC_2.DOC
2-3
GENERAL SAFETY INSTRUCTIONS
Section 2
1. Saw blade during cutting or material feed mechanism
2. Wire brush unit
3. Chip conveyor unit
4. Speed reducer
5. Hydraulic motor/pump
6. Belt transmissions variable speed motors
7. Blade motor
8. Coolant Pump
9. Drive wheel
10. Parts, machine not assembled tightly causing mechanical vibration
When your machine is running, noise will come out. This is a machine-electric interface problem
that may make people feel uncomfortable. Our products pass noise testing under 78 dBA. If your
machine produces an undesirable noise while it is running, you should:
1. Be sure maintenance schedule has been followed exactly.
2. If yes, follow section 9 in this manual for system troubleshooting procedures.
SEC_2.DOC
2-4
GENERAL SAFETY INSTRUCTIONS
Section 2
The emergency stop switch on the control panel is a red button (with rubber material). It is used
for emergency stop at any circumstance.
The saw wheel cover interlock switches located on the two wheel housings are used to
assure that the machine will stop whenever the wheel covers are open. This device is to protect
users from being cut by the running saw blades. The vise clamp switch is to assure firm clamping
of the workpiece. If the workpiece is not clamped properly, the saw blade is not allowed to run.
Among all these safety switches, some of them are used to protect the users and some of
them are used to prevent damage to saw blades, the workpiece and the machine itself, etc. We
have taken every precaution to prevent injury or damage and to provide safe and economical
operation of the machine.
Guard mountings:
The locations of all safety guards on the machine are indicated above. All of these protectors
should always be mounted on the machine whenever the machine is running. Users are not
allowed to move any of these elements under any circumstances except when servicing the
machine. However, even skilled service technicians still have to be very careful when performing
repairs or service on the machine with any of these protectors removed. It is the responsibility of
the user to make sure all these elements is not lost and damaged.
SEC_2.DOC
2-5
GENERAL SAFETY INSTRUCTIONS
Section 2
GROUND DIAGRAM
MOTOR
PLC
UNIT
MOTOR
Transformer
GROUND PLATE 1
L1
DOOR
L2
L3 GROUND PLATE 2
PE
ELECTRICAL CABINET
CHASSIS BODY
EMC PROTECTION
S1
K1
SEC_2.DOC
2-6
GENERAL SAFETY INSTRUCTIONS
Section 2
entering a signal line due to electromagnetic induction is considered due to the magnitude of
noise change rate rather than due to the noise crest value of the noise generating source. The
attenuation waveform of the RC is therefore less unlikely than the pulse waveform of the
arrester to cause electromagnetic induction. The RC compound element is thus considered better
in noise elimination.
Due to the reasons mentioned above, mount a RC compound element on each of AC motor,
AC solenoid and AC control relay.
SEC_2.DOC
2-7
MOVING AND INSTALLATION
Section 3
SECTION 3
3.1 INTRODUCTION
Your machine is made of three main system components: Machine equipment, hydraulic
system, and electrical control system. Please read the entire manual carefully to obtain a thorough
knowledge of the machine. This section describes how to move and install the machine to prevent
personal injuries and machine damage. Do not operate the machine by guesswork. Keep the manual at
hand and refer to it whenever you are not sure of how to perform any of the procedures.
As far as the moving of the machine is concerned, please follow the carrying and cleaning
method to keep your machine in the best working condition. You can choose any one method as
following to move your machine:
A. CARRYING:
Carry the machine to its location by using a crane and a wire rope sling that can fully
withstand the weight of the machine( your machine weight about 2200 Kgs). Apply the wire rope sling
to the lifting hooks at the rear of the front vise slide and to the rear end of the machine. Slowly lift the
machine while taking care so that the machine is not shocked and that the wire rope does not interfere
with the saw-head.
Sec_3.DOC
3- 3
MOVING AND INSTALLATION
Section 3
Sec_3.DOC
3- 4
MOVING AND INSTALLATION
Section 3
2. Use forklift to place
Sec_3.DOC
3- 5
MOVING AND INSTALLATION
Section 3
3. Use rolling cylinder to place
You can use this method to move your machine when it is in the small machine shop .
B. CLEANING
After the machine has been spotted on the designated position, remove the rust-preventive
grease with wiping cloth dampened with cleaning oil or kerosene. Apply machine oil to the machine
surfaces that are susceptible to rusting.
( Do not remove the rust-preventive grease with a scraper or the like. Do not wipe the painted
surfaces with solvent.
This band saw machine has been designed and manufactured in accordance with the latest
technical standard on safety regulations. Naturally, such a machine tool has a few potentially
hazardous locations. So, we strongly suggest following the general rules and regulation on safety
precautions and particularly those, given below:
Sec_3.DOC
3- 6
MOVING AND INSTALLATION
Section 3
Please avoid using same power supply with electric spark machining, electric welder.
Because of unstable electric tension, it may prevent your machine electric installation
from working properly.
Please connect with power supply independently and directly.
Please use correct electric capability, electric tension, 50/60 Mz.
( Supply electric power to the machine from a source different from those for welding or
other machines that produce electric noise. Ground the machine with an independent
grounding conductor.
( Limit the supply voltage variations to within ± 10%
Have to connect to earth to ground machine.
3.3.4 Unpacking
After the machine has been properly positioned, remove the shipping bracket.
Unpack your machine carefully. Do not damage the machine surface paint.
Remember to remove the bracket used to lock the saw frame and the saw bed.
Be sure to retain this bracket so that it can be used again in the event that your machine
must be relocated.
BRACKET
Sec_3.DOC
3- 7
MOVING AND INSTALLATION
Section 3
3.3.5 Equipment Furnished
Your machine has a set of tools to maintain machine to keep it running. Cutting ease and
efficiency can be maintained with proper care. We list the standard accessories and illustration as
follows :
1. Tool box 1 pc
2. Grease gun 1 pc
3. Screw drive(+, -) 2 pcs
4. Open end spanner 3 pcs
5. Hexagon wrench 1 set
6. Operation & parts book 1 pcs
Sec_3.DOC
3- 8
MOVING AND INSTALLATION
Section 3
Machine leveling
Place spirit levels on the vise slide plates and the work feed table, and adjust the left-
and-right and fore-and-aft level of the machine with leveling bolts.
The fore-and-aft level should be adjusted correctly. The level of the rear of the machine
is approximately 10 mm higher than the level of the front end. This will allow the
proper return of the cutting fluid for working. The illustration is as follows:
( Be sure to ascertain that all leveling bolts evenly support the weight of the machine.
Sight Gauge
Drain Plug
Sec_3.DOC
3- 9
MOVING AND INSTALLATION
Section 3
Hydraulic oil supply
Open the filler cap. Please fill the hydraulic oil tank with the hydraulic oil furnished with the
machine. Check the sight gauge to ascertain the oil level in the tank. (Oil tank should be full
already if it is a new machine)
Filler Cap
Sight Gauge
0 100 110
Sec_3.DOC
3- 7
MOVING AND INSTALLATION
Section 3
3.4 WORKING CONDITIONS
Sec_3.DOC
3- 8
OPERATING INSTRUCTION
Section 4
SECTION 4
OPERATING INSTRUCTION
Cutting method:
If you choose dry cutting and low speed of saw blade, the chips may accumulate in machine parts and
may cause the operation or insulation failure of the machine. We suggest you choose wet cutting to
avoid machine damage. You can refer to chapter 7 for experience data.
Cutting oil:
If economics are not of critical concern, you can try oil-based cutting fluids. We always suggest you to
use water-soluble cutting fluids. The comparison table for it is as follows:
SEC_4.DOC
4-1
OPERATING INSTRUCTION
Section 4
Advantage Disadvantage
Have high cooling effect Remove paint
Not flammable Lose rust protection effect when deteriorated
Economical Foam
Does not require cleaning of cut products Putrefy
(especially when soluble)
Decline in performance, depending on quality of
water used for dilution
If Shell Dromus BS or Shell Lubricool Yellow Cutting Fluid is used, the ratio of cutting fluid to water
should be approximately 1:15~1:20. Check the sight gauge to ascertain the fluid level in the tank. Tank
capacity: 38 liters(10 gal.)
Never work with pure water only.
SEC_4.DOC
4-2
OPERATING INSTRUCTION
Section 4
1. POWER indicator lamp
Indicates that the power of band saw machine is turned on. Light comes on when you turn on
machine circuit breaker switch on the electrical enclosure for machine. This lamp indicates
preparation for start-up.
NOTE: The swiveling operation must be done only at the following situation.
. Blade stops.
. Saw frame at upper limit position.
. Vises open.
No. 4
No. 8
SEC_4.DOC
4-3
OPERATING INSTRUCTION
Section 4
6. VISE SELECTOR AND PUSH BUTTON
Turn the selector to “ ” position and depress the push button, the vises clamp. The clamping
is held after releasing button due to its auto holding function. Turn the selector to “ ”
position and depress the push button, the vises open. The opening operation stops after releasing
button due to its non-auto holding function.
9. SAWHEAD UP BUTTON
When this button is depressed, the sawhead raises until the upper limit switch is actuated..
SEC_4.DOC
4-4
OPERATING INSTRUCTION
Section 4
Saw Blade Speed Control Panel
1 2
SEC_4.DOC
4-5
OPERATING INSTRUCTION
Section 4
4.4 MANUAL OPERATION
1. Select the saw blade best suited for the workpiece to be cut. Size and shape of the workpiece, and
type of material should all be considered when selecting the saw blade to be used. (ref. Sec. 7)
2. Place the saw blade onto both the drive and driven wheels.
1) Turn the circuit breaker ON.
2) Depress the hydraulic ON button to start the hydraulic pump motor.
3) Depress the blade up button and raise the saw head until the right insert holder completely
clears the front fixed vise.
Insert Holder
4) Turn the tension handle “ ” to “ ” position to move the driven wheel toward the
drive wheel.
Lock Lever
7) Place the saw blade on both the drive and driven wheels.
8) Insert the saw blade into both the left and right inserts so that the back edge of the saw blade
securely touches the back-up rollers of each insert.
9) Properly position the saw blade on the drive wheel so that the back edge of the saw blade
makes secure contract with the flange of the drive wheel. Then engage the blade holder with
the blade to prevent its dislocation from the drive wheel.
The blade holder will disengage as the saw blade begins rotating.
SEC_4.DOC
4-6
OPERATING INSTRUCTION
Section 4
10) Ensure that the back of the saw blade makes contact with the flange of the driven wheel.
Turn the tension handle to “ ” position so that sufficient tension is placed on the saw
blade. Proper blade tension is obtained.
Ensure that the back edges of the saw blade make contact with the flanges of the drive and
driven wheels. Check the saw blade to insure that it it properly positioned on both the drive
and driven wheels.properly positioned on both the drive and driven wheels.
11) Tighten the insert lock bar to lock left insert securely.
12) Close the covers of both the drive and driven wheel.
Proper Improper
SEC_4.DOC
4-7
OPERATING INSTRUCTION
Section 4
3) After adjusting the position of the blade guide arm, tighten the lock handle to lock the blade
guide securely.
When tightening the lock handle, gently swing the lower end of the blade guide alternately
to the left and right so that the dovetail is properly aligned.
4) Tighten the left insert.
5) Close the wheel covers.
Fluid Flow
Control Lever
SEC_4.DOC
4-8
OPERATING INSTRUCTION
Section 4
• If the saw chips are sharp and curved, increase the flow of cutting fluid.
• If the saw chips are grained, reduce the flow of cutting fluid.
......
..........
........ ........
......... .........
....
...........
....
Before depressing the blade drive button, insert the cleaning hose nozzle into the wire brush case.
IMPORTANT:
After the day’s work, be sure to lower the saw blade to the lower limit position after removing the
workpiece.
Please follow the instruction on control panel when perform miter cutting. The operation should
also be in accordance with the flow valve operation. An angle indicator is on the front base of
machine. The indicator is only good for reference. A more precisive angle can be obtained by
using an angle gauge to measure the angle between fixed vise and blade.
SEC_4.DOC
4-9
OPERATING INSTRUCTION
Section 4
Loading test:
1. First, you have to preset cut length and the number of cuts required before clamping the workpieces
with rear vise clamp for cutting
2. Start cutting
If you press the button to close the front vise, please move ahead rear vise carefully to avoid vise
deformation at front vise touch rear vise situation.
3. Gauge workpieces
SEC_4.DOC
4-10
OPERATING INSTRUCTION
Section 4
Item Design value
Blade tension 2500 kg (1.27 inch saw blade,
another case, refer chapter 7 )
Hydraulic pressure 35~38 kg/cm2
Reducer gearing temperature 150 ~550 C
If you try to test band saw cutting for your workpieces, please refer to chapter 7.2 and 7.3 for speed
chosen. It is easy to operation if you practice a couple of hours.
SEC_4.DOC
4-11
OPERATING INSTRUCTION
Section 4
Installing saw blade:
1. Move saw head upward against stop.
2. Open the wheel cover.
3. Open the driven-side saw blade safety cover.
4. Pull down the saw blade insert.
5. Turn the saw blade tension lever to “ ” position to move the driven wheel close the drive
wheel.
6. Loosen the wire brush lock lever, and lower the wire brush.
7. Clean the saw band guides before installing a new saw blade.
8. Install the saw blade on the drive and driven wheels with the cutting edge facing down.
Wear leather gloves when handling the saw blade.
9. Put the saw blade into the left-hand and right-hand saw blade inserts. When the back of the saw
blade is pressed against the backup rollers(backup tip) in each saw blade insert, pull up the saw
blade insert open/close levers to clamp the saw blade.
10. Press the back of the saw blade against the flange of the drive wheel, and hold the saw blade with
the blade holder.
The blade holder will automatically release the saw blade when the saw blade starts running.
11. Press the back of the saw blade against the flange of the driven wheel, and turn the saw blade
tension lever to the “ ” position. The saw blade will be tensioned to the proper degree.
12. Pull up the saw blade insert open/close levers.
13. Close the saw blade safety cover and gently close the wheel cover.
14. Press the blade drive button to start the saw blade running.
15. Open the wheel cover and check to see that the saw blade is not off the drive and driven wheels
and is securely pressed against the backup rollers(backup tips).
16. Move chip of wire brush back to cleaning position. Adjust brush allowing the tips to run free
through the bottom of the teeth and tighten the lock lever.
17. Close the wheel cover.
STOP
SEC_4.DOC
4-12
HYDRAULIC SYSTEM
Section 6
SECTION 6
HYDRAULIC SYSTEM
6.1 INTRODUCTION
The band saw model for your device is a hydraulic driven billet machine. Most of the
movement of the machine elements are powered by the hydraulic system. For example, the lifting of
the saw head is driven by hydraulic cylinder. The tension of the saw blade is also adjusted through a
hydraulic cylinder mounted on the back of left saw wheel housing. The clamping of the workpiece is
also done by the power of two sets full stroke hydraulic cylinders.
SEC_6.DOC
6-1
BAND SAW CUTTING - A PRACTICAL GUIDE
Section7
SECTION 7
7.1 INTRODUCTION
COSEN band saw machines are designed to be installed with high quality using high speed
saw blades for maximizing productivity. To be able to use this kind of high performance band saw
blade, the machine has to be of rugged design, have high quality saw blade guides, have sufficient
motor horse power for high saw band speeds, and has to be able to apply necessary tension to the saw
bands. Your COSEN machine has all these features to provide a better service for you.
The saw blade is guided through the cutting area by roller guides to keep it straight as it
comes off the driving wheels. The precision carbide inserted guides then holds the blade securely and
accurately throughout the sawing process. The tension of the saw blade is adjusted through the
tensioning device on the strong saw bow. The cutting feed and down feed pressure of the blade is
regulated automatically by hydraulic regulation.
Tooth spacing
Tooth Set
Depending on the hardness of the material the cutting rate will increase or decrease. For
example, it takes more time to cut stainless steel than to cut cast iron.
SEC_7.DOC
7-1
BAND SAW CUTTING - A PRACTICAL GUIDE
Section7
The surface conditions will also affect the cutting rate. If there are places on the surface on
the material which are hard, a slower blade speed will be required or blade damage may result.
It will be slower to cut tubing than to cut solids, because the blade must enter the material
twice, and because coolant will not follow the blade as well.
Tough or abrasive materials are much harder to cut than their machinability rating would
indicate.
Tooth spacing is determined by the hardness of the material and its thickness in cross section.
Tooth set prevents the blade from binding in the cut. It may be either a "regular set" (Also
called a "Raker Set" ) or a "Wavy Set".
The regular or raker set is most common and consists of a pattern of one tooth to the left. Set
to the right, to the left and one which is straight, or unset. This type of set is generally used
where the material to be cut is uniform in size and for contour cutting.
Wavy set has groups of teeth set alternately to right and left, forming a wave-like pattern.
This reduces the stress on each individual tooth, making it suitable for cutting thin material or
a variety of materials where blade changing is impractical. Wavy set is often used where
tooth breakage is a problem. This is shown in Fig. 7.1 as follows:
Right
Straight Left
Regular(raker) Set Wavy Set
Fig. 7.1 The saw set
Blade selection:
There are five types of blade material generally used:
• Hard-back carbon
• Semi-high speed
• High speed
• Carbon
• Electron-welded blade
In most high speed production cutting either the semi-high speed or the electron-welded band are
used. Electron welded blade is the best blade. But it is also the most expensive. To construct the
electron-welded blade, M-2 tool steel is welded to the blade back. Therefore the blade is capable
of very high surface speed. The semi-high speed blade is used more in structural because it is
capable of taking a great deal more abuse. The hard-back carbon blade's teeth does not have red-
hardness but if the blade is run slowly it can be very economical. We do not recommend carbon
blades because the back of the blade is not sufficiently strong to stand adequate tension and
because it has poor resistance to heat and abrasion. Usually, the coarse hook tooth blade will give
better results, but accurate feed control is a must with a coarse tooth blade.
SEC_7.DOC
7-2
BAND SAW CUTTING - A PRACTICAL GUIDE
Section7
Flexible
Back
Weld
Guide Spacing:
The rigidity of the blade is a function of guide spacing, with rigidity being reduced to the third
power as the distance between the guides increases. For example, with guides spaced 2 inches
apart, blade deflection might be approximately 0.2. Under the same conditions, but with the
guides spaced at 4 inches apart, blade deflection would be approximately 0.8.
This is a much simplified version of the formula, because it does not consider band tension or
guide design. It is important to recognize, for example that rollers are considered as a pivotal
contact. Whereas carbide faces could be considered as anchored supports. A more complete
deviation, including band tension and guide design, is included in Roark's handbook, "Formula
for stress and strain".
SEC_7.DOC
7-3
BAND SAW CUTTING - A PRACTICAL GUIDE
Section7
1. The thinner the stock, the finer the saw pitch
2. The thicker the stock, the coarser the saw pitch
3. The more difficult the stock, the finer the saw pitch
4. The softer the material , the coarser the saw pitch
Always have at least three teeth in contact with the material being cut.
Solid Stock:
SEC_7.DOC
7-4
BAND SAW CUTTING - A PRACTICAL GUIDE
Section7
Solid:
You can refer to the feed and speed chart (Metric Table) as follows:
SEC_7.DOC
7-5
MAINTENANCE & SERVICE
Section 8
SECTION 8
8.1 INTRODUCTION
For the best performance and longer life of the band saw machine, a maintenance schedule is
necessary. Some of the daily maintenance usually takes just a little time but will give remarkable
results for the efficient and proper operation of cutting.
1. Please check the hydraulic oil level, adding oil as necessary.(middle level is better)
2. Please check the cutting fluid level, adding fluid as necessary. If the fluid appears contaminated
or deteriorated, drain and replace it.
3. Please check the saw blade to ensure that it is properly positioned on both the drive and driven
wheels.
4. Please make sure that the saw blade is properly clamped by the left and right inserts.
5. Please check the wire brush for proper contact with the saw blade. Replace the wire brush if it
is worn out.
SEC_8.DOC
8-1
MAINTENANCE & SERVICE
Section 8
2. Lubricate the following points:
• Vise slide plates
Recommended Grease:
Shell Alvania EP Grease 2
Mobil Mobilplex 48
1. 3.
2. 4.
2. Please replace the transmission oil after the first three months (or 600 hours of operation).
Thereafter, every six months (or every 1200 hours of operation), whichever occurs first, check the
sight gauge to ascertain the transmission oil level. Lubricant oil must have a viscosity sufficient
SEC_8.DOC
8-2
MAINTENANCE & SERVICE
Section 8
to reduce friction of the worm and worm gear. So that the gear reducer can operate smoothly
under high load and impact.
Recommended Oil:
Omala oil R220
Mobil Gear 630
Sight Gauge
SEC_8.DOC
8-3
SYSTEMS TROUBLE SHOOTING
Section 9
SECTION 9
9.1 INTRODUCTION
All the machines being manufactured by COSEN pass a 72 hours continuously running test
before shipping out and COSEN is responsible for the after sales service problems during the warranty
period if the machine are used normally. However, there still exist the some unpredictable problems
which may disable the machine from operating.
Generally speaking, the system troubles in this machine model can be classified into three
types, namely GENERAL TROUBLES, MOTOR TROUBLES and BLADE TROUBLES. Although
you may have other troubles which can not be recognized in advance, such as malfunctions due to the
limited life-span of mechanical, electric or hydraulic parts of the machine.
As a twenty year old company, COSEN has accumulated enough experiences and technical
data to handle all of the regular system troubles. Meanwhile, the engineering department of COSEN
had been continuously improving the machines to prevent all possible troubles.
It is hoped that you will give COSEN your maintenance experience and ideas so that both
sides can achieve the best performance.
9.2 PRECAUTION
When an abnormality occurs in the machine during operation, you can do it yourself safely.
If you have to stop machine motion immediately for parts exchanging, you should do so according to
the following procedures:
• Press EMERGENCY STOP button .
• Open the electrical enclosure door.
• Turn off breaker.
SEC_9sh.DOC
9-1
SYSTEMS TROUBLE SHOOTING
Section 9
9.3 GENERAL TROUBLES AND SOLUTIONS
Motor stalls Excessive head pressure Reduce head pressure. Refer to Operating Instructions
“Adjusting Feed”.
Excessive blade speed Refer to Operating Instructions “Speed Selection”.
Improper blade Refer to Operating Instructions “Blade Selection”.
selection
Dull blade Replace blade.
Guide rollers not Refer to Adjustments.
adjusted properly
Cannot make Rear vise jaw not Set fixed vise jaw 90° to blade.
square cut adjusted properly
Excessive head pressure Reduce head pressure. Refer to operating instructions
“Adjusting Feed.”
Dull blade Replace blade
Increased cutting Insufficient head Increase head pressure. Refer to Operating Instructions
time pressure “Adjusting Feed.”
Reduce blade speed Refer to Operating Instructions “Speed Selection.”
Motor running in wrong Reverse rotation of motor (Motor rotation C.C.W. pulley
direction end.)
Will not cut Blade teeth pointing in Remove blade, turn blade inside out.
wrong direction Re-install blade. (Teeth must point in direction of
travel. )
Hardened material Use special alloy blades (Consult your
Industrial Distributor for recommendation on type of
blade required.)
SEC_9sh.DOC
9-2
SYSTEMS TROUBLE SHOOTING
Section 9
9.4 MOTOR TROUBLES AND SOLUTIONS
SEC_9sh.DOC
9-3
SYSTEMS TROUBLE SHOOTING
Section 9
SEC_9sh.DOC
9-4
SYSTEMS TROUBLE SHOOTING
Section 9
Use of blade with incorrect pitch Use blade with correct pitch suited
to workpiece width
Failure to break-in saw blade Perform break-in operation
Excessive saw blade speed Reduce speed
Insufficient saw blade speed Increase speed
Excessive saw head descending speed Reduce speed
Insufficient saw head descending speed Increase speed
Insufficient saw blade tension Increase tension
Wire brush improperly positioned Relocate
Blade improperly clamped by insert Check and correct
Improperly clamped workpiece Check and correct
Excessively hard material surface Soften material surface
Excessive cutting rate Reduce cutting rate
Non-annealed workpiece Replace with suitable workpiece
Insufficient or lean cutting fluid Add fluid or replace
Vibration near machine Relocate machine
Non-water soluble cutting fluid used Replace
Air in cylinder Bleed air
Broken back-up roller Replace
Use of non-specified saw blade Replace
Fluctuation of line voltage Stabilize
Adjustable blade guide too far from Bring blade guide close to
workpiece workpiece
Loose blade guide Tighten
Blue or purple saw chips Reduce cutting rate
Accumulation of chips at inserts Clean
Reverse positioning of blade on machine Reinstall
Workpieces are not bundled properly Re-bundle
Back edge of blade touching wheel flange Adjust wheel to obtain clearance
Workpi ece of insufficient diameter Use other machine, suited for
diameter of workpiece Replace
Saw blade teeth worn Replace
SEC_9sh.DOC
9-5
SYSTEMS TROUBLE SHOOTING
Section 9
9.7 MINOR TROUBLE SHOOTING
NOTE:
BEFORE ANY ADJUSTMENT OR MENTENANCE OF THE MACHINE, PLEASE
MAKE SURE TO TURN OFF THE MACHINE AND DISCONNECT THE POWER
SUPPLY.
If the feeding table suffers the huge stroke and the alignment is effected, follow the below procedure to
adjust.
TOOL, measuring
Measurement, Horizontal balance
Procedure
1. Screw or loosen the adjusting bolt to attain the horizontal balance (leveling) between the roller
table and the machine frame.
2. Ensure that the machine frame is not struck by the loaded material on the feeding table.
3. Check the leveling by the measuring tool.
4. After finished the adjusting, fix the roller table.
Warning:
If the feeding table and the machine frame are not positioned under the horizontal balance, the
loaded material may be going up gradually and affect the cutting effect.
SEC_9sh.DOC
9-6
SGB-71091
SGB-71090
SGB-71092
SGB-71091
SGB-71092
CHANGED TO SGB-71086
CHANGED TO SGB-71087
SUGGESTION SHEET DATE / /
SUGGEST.DOC
PLEASE FOLD, SEAL, AND MAIL TO COSEN
Stamp
To:
COSEN MACHINERY INDUSTRIAL CO., LTD.
Customer Service Department
110 Ching-Fu Street
Hsin-Chu 300
Taiwan, R.O.C.
Tel:886-3-5332143
cosen@ms9.hinet.net
ENVELOPE.DOC
COSEN MACHINERY INDUSTRIAL CO., LTD.
110, CHING-FU STREET, HSIN-CHU, TAIWAN, R. O. C.
TEL 886-3-5332143-5
FAX 886-3-5348324
e-mail cosen@ms9.hinet.net