Sawing Machine Faults and maintenance

Sawing machines, as commonly used cutting equipment in metal processing, their stable operation directly affects production efficiency and safety. Based on the common types of faults, systematic troubleshooting and maintenance can be carried out from four dimensions: ‌ mechanical, hydraulic, electrical, and operating parameters ‌.

I. Common Fault Types and Cause Analysis

1.Broken band (saw band broken) ‌

This is one of the most frequent malfunctions. The main causes include:

Excessive or insufficient tension: If the tension is too high, it exceeds the load-bearing limit of the saw band; if it is too low, it will cause the saw band to vibrate and accelerate wear.

Improper clearance or wear of the guide block: Excessive pressure on the saw back causes stress concentration at the tooth root, resulting in cracks.

Saw wheel wear or excessive runout: Axial and radial runout cause impact loads, resulting in instantaneous band breakage.

The workpiece is not clamped tightly or the feed rate is too large: The cutting load suddenly increases, which is prone to cause tooth breaking or chipping.

Insufficient coolant or improper proportioning: Excessively high temperature at the tooth tip causes the material to soften, accelerating wear and even fracture.

✅ ‌ countermeasures ‌ : Regularly inspect the tensioning system, replace worn guide blocks and saw wheels, standardize the clamping process, and reasonably set the feed rate and coolant concentration.

2. The sawn surface of ‌ is rough and uneven ‌

Blunt or damaged teeth: The saw band has been in use for too long or the "running-in" is not in place.

Excessive feed rate or insufficient tension: This leads to uneven force distribution on the sawteeth.

Insufficient cutting fluid or clogged nozzles: Ineffective lubrication and chip removal;

Excessive vibration of the sawing machine is caused by lack of oil in the guide rails, loose sliders or unstable foundation.

✅ ‌ countermeasures ‌ : Adjust the feed parameters, clean the nozzle and replenish the cutting fluid, check the lubrication status of the guide rail, and replace the saw band with a new one if necessary.

3. The ‌ saw frame cannot rise or fall ‌

This problem is mostly related to the ‌ hydraulic system ‌. Common causes are as follows:

Limit switch fault ‌ : oxidation of contacts or circuit disconnection, resulting in no signal feedback;

Blockage or jamming of solenoid valve ‌ : iron filings contaminate the valve core, affecting the on-off of the oil circuit;

Insufficient hydraulic pressure ‌ : the set value of the relief valve is too low, the oil pump delivers insufficient oil, or the oil is turbid;

Internal leakage in the cylinder or damage to the piston seal ring ‌ : causes pressure leakage, slow action or no response;

There is air in the system ‌ : Loosen the exhaust screw to expel the air bubbles.

✅ ‌ recommended processing flow ‌ :

Check whether the upper limit switch is reset.

Measure whether the system pressure is within the range of 2.5 to 3.5MPa.

Clean the solenoid valve and filter screen, and replace the aged sealing parts;

Remove the air from the oil circuit to ensure the hydraulic oil is clean.

4. Makes screaming or abnormal noises when sawing ‌

The sawing speed is too fast or the feed rate is too large;

The guide block is too tight or there are hard points in the material;

Improper selection of coolant or incorrect injection Angle;

The aging and loosening of the drive belt cause intermittent loss of rotation.

✅ ‌ countermeasures ‌ : Reduce the saw speed and feed rate, adjust the guide block clearance, replace the coolant, and inspect and replace the drive belt.

5. Sawing skew (sawing skew) ‌

The spacing of the guide arms is too large or they are not on the same horizontal plane.

Insufficient tension of the saw blade or improper selection of the tooth profile;

The workpiece is not firmly clamped or the hydraulic system is unstable.

The saw blade has asymmetrical teeth or insufficient running-in.

✅ ‌ solution suggestion ‌ : recalibrate the position of the guide arm, select a saw band with an appropriate pitch, and ensure that the workpiece is completely fixed.

Ⅱ. Preventive Maintenance Suggestions

To reduce sudden malfunctions, it is recommended to carry out the following daily maintenance