Horizontal Bandsaw

The horizontal bandsaw is a type of power saw widely used in metalworking and fabrication shops for cutting metal stock to length, distinct from its vertical counterpart which is typically used for contour cutting. The horizontal configuration is designed primarily for cutting large sections of material to specific lengths with minimal operator intervention. This makes it ideal for production environments where consistent and repetitive cuts are required. Horizontal bandsaws with hydraulic feed are essential in production and industrial environments where accurate, repeatable cuts are necessary. Unlike gravity-fed or manually-operated saws, the hydraulic system allows for fine control over the cutting rate, ensuring consistent performance across different materials and cross-sections.

These saws are commonly found in machine shops, steel fabrication facilities, and maintenance departments. They are available in various sizes, from small benchtop models to large industrial machines capable of cutting beams and heavy stock.

Overview

A horizontal bandsaw It features a long, continuous blade mounted horizontally, with teeth along one edge, which is looped over two wheels. The saw blade is drawn downward into the workpiece, enabling efficient and precise straight cuts, especially in metal bars, tubes, and structural materials. This type of bandsaw incorporates a hydraulic feed system to control the descent and pressure of the cutting head, providing smooth, controlled cuts and minimizing blade wear. Though most commonly used for metal, some horizontal bandsaws can also be adapted for cutting plastics and other non-ferrous materials.

A typical horizontal bandsaw consists of the following main parts:

Blade: A continuous loop with cutting teeth, usually made of high-speed steel or bi-metal materials.
Wheels: Two wheels (drive and idler) guide and tension the blade.
Cutting Head: The pivoting arm that houses the blade and descends into the material.
Vise: A clamping mechanism that secures the workpiece during cutting.
Bed/Table: A horizontal platform that supports the material being cut.
Motor: Powers the blade, via a belt or through a gearbox.
Coolant System: Helps reduce blade wear and cool the workpiece.
Hydraulic Feed: Regulates the rate at which the saw head lowers during cutting. Includes a hydraulic cylinder, control valve, and often a feed rate adjustment knob.
Control Panel: Includes power switches, emergency stop, and hydraulic feed controls.

Safety First

Before operationg a horizontal bandsawː

Wear appropriate personal protective equipment (PPE), including safety glasses and steel-toe shoes.
Ensure all guards are in place and functioning.
Secure your piece.
Make sure the blade is in good condition.
Verify the coolant system is filled and operational.

Operating Instructions

Step-by-Step Operation

Position the Material: Place the workpiece in the vise and align it for the desired cut. Use a stop block or scale for repeat cuts.
Secure the Workpiece: Place the material in the vise and tighten securely. Ensure it is aligned for a square cut.
Start the Saw: Turn on the saw and coolant pump and adjust coolant flow.
Set Hydraulic Feed Rate and Lower the Blade: Adjust the speed according to the material type and thickness. Use the hydraulic control valve to set the desired descent rate of the saw head. Begin the cut by slowly lowering the saw head onto the workpiece, using the feed system. Softer materials use higher speeds; harder materials require slower speeds. Ask staff if unsure.
Monitor the Cut: Ensure the blade is cutting smoothly without binding or excessive vibration. Adjust feed rate or stop the machine if necessary.
Complete the Cut: Allow the saw to finish cutting through the material. Once complete, the blade should stop automatically, or you can hit the stop button.
Raise the Blade and Remove Material: Lift the saw head manually and release the vise. Carefully remove the cut piece and prepare for the next cut if needed.

Maintenance and Care

General Maintenance

Degreasing and oiling the bed.
Clean machine, remove chips and debris from the bed.
Clean and refill coolant tanks, and clear nozzles.
Check fluid levels, inspect for leaks, and test the feed control valve regularly.
Inspect for wear, replace dull or damaged blades
Inspect electrical components

Proper maintenance ensures longer machine life and improved cutting performance.

Changing the blade

Removing the blade

Unplug the Machine: Be sure there is no power in the bandsaw.
Remove Red Guards: Loosen the 2 bolts from the top guard and slide the red plaque out. Do the same for the bottom guard.
Loosen the Blade: Unscrew the knob on the side of the bandsaw until it’s completely loose.
Unhook the Blade: Open the hood flaps to gain access to the blade. Wearing work gloves, push the wheel inward all the way. Then grab the blade and pull it free, it should slip out easily. Repeat on the other side.
Remove the Damaged Blade: The blade is still pinched between the two arms in front of the machine. To remove it, push the blade down and away from you, turning it in a clockwise motion. That should free it completely.

Disposing of the blade

Coiling the Blade: Hold the blade up in front of you and press your foot down on the bottom of it, pinching it against the floor. Still wearing gloves, grab the blade and twist it with two hands until it folds onto itself.
Securing the blade: Once it makes a small tidy bundle, do not let it go. Use welding wire or zip ties to fasten around it, preventing it from popping open.
Throwing it out: Dispose of the damaged blade in the metal only garbage. If the blade is still good, put it away in storage.

Installing the New Blade

Opening the Blade: Do not let go of the coil. Cut off the zip ties keeping it together. If the blade has plastic covering its teeth, carefully undo the coil and take off the cover once its fully opened. If not, let go of the blade, letting it bounce on the ground away from you and open on its own.
Slotting the Blade: Insert the blade into the slot at the top of the machine, leaving it within the hood but free of the wheels.
Placing the blade: Grab the blade at the bottom, where it’s not in contact with the machine. You’ll have to twist it so that it stands vertically, with its teeth at the bottom. Then, manoeuvre it under the two arms in front of the machine and slide it up into the slot, between the bearings.
Position the blade: Grab an extra pair of hands, then place the blade around the wheels so that it slots into the hood. One at a time, push the blade into place so that it slots itself into the lip of the wheel and hold it there. Keeping it slotted, lift the blade up until it touches the top of the wheel.
Tensioning the blade: Still holding the blade, start screwing the knob on the side of the bandsaw until the blade can hold itself up. Once you’ve let go, keep tightening the knob to spec. The Brunsfield Horizontal Bandsaw, specifically, should be tensioned to 2750 psi.
Reinstalling the guards: Slide the guards back into place and tighten the set screws. Make sure the bottom guards are fully tightened as the blade might rub against them if they’re not.

Tensioning the blade

The horizontal bandsaw in Brunsfield Center should be ideally tensionned at 2750 psi. To adjust the tension, tighten/loosen the knob on the side, near the handle. There is a pressure gauge at the back of the bandsaw for readings.

Adjusting the guard

To adjust how much of the blade is covered, simply loosen the big set screw on the arms and slide it along the blade. Be careful to keep the guard slotted into the hood of the machine and not let it hang. Make sure that all guards and set screws are tightened before you start machining.

Mixing and inserting coolant

Adding coolant

The horizontal bandsaw uses the white type of coolant, which is stored inside a white bucket near the machine, ask staff if you can't find it. To add more coolant to the machine, pull out the white reservoir that is underneath the bandsaw and pour coolant into the opening on the top or simply pour coolant into the bed of the machine as it will drain into the reservoir.

Mixing coolant (STAFF ONLY)

To make more coolant, you'll need a Coolant King jug found in the MTC closet (that is the brown stuff that turns white). Pour it into the white coolant bucket until it reaches the ''Coolant Level'' line. Fill the rest with water up to the ''Whorter Level'' line.

PRO TIPː test to see that you're using the right product. Pour a bit of coolant concentrate into a cup and add water. It should turn white. If it doesn't, it might not be the right product.