Efficient sawing of aluminum: though it's easy to saw, this material can be difficult to saw productively and cost-effectively. Here are some tips

Modern Machine Shop, Nov, 2002 by Dallas Stuck, Frank Tielli

Manufactured by Kaltenbach, Inc. (Columbus, Indiana), the KBS-DG line of two-way miter-cutting bandsaws features a cutting envelope as large as 29.5 by 19.7 inches. The machines may be used as stand-alone shop equipment or in combination with the company's line of material handling and length measuring systems. These systems are designed for steel service centers and other large-scale fabricating operations.

The KASTOtwin series of German-made, high performance bandsaws is available from Kasto-Racine, Inc. (Export, Pennsylvania). These machines include both fully-automatic and semiautomatic models with a maximum cutting envelope of 15.75 by 15.75 inches. Automatic machines are controlled by the company's "CompactControl." This NC control incorporates functions such as incremental feed, zero stop and job memory for 30 data sets of length/number combinations. The band speed control allows adjustment from 65 to 360 fpm. The machine control electronically monitors minimum rpm to shut off the drive motor when the band speed is too low. The control unit detects band tension and breakage, in addition to clamping pressures.

Cost-Per-Cut Calculation

Machine/Labor Cost includes:

Cost of machine lime, excluding blade

Ceiling lime

Idle time between cuts

Total cycle lime

Time per piece (single or bundle)

Blade Cost includes:

Price of blade

Duration of blade change

Cost of machine time, excluding blade

Cast of blade change

Total cost of blade

Number of pieces cot by the blade

Cost per piece from blade

Total Cost Per Piece=Machine/Labor Cost Blade Cost

About the authors: Dallas Stuck and Frank Tielli work for Bahco North America, Inc., of Scranton, Pennsylvania. Mr. Stuck is manager of bandsaw business development. Mr. Tielli is a technical advisor.