Optimization of tooth profile parameters of bimetal band saw blades
Cutting materials is the first step in mechanical processing, and compared to flame cutting and wire cutting, band saw cutting is the most efficient method for material saving and energy conservation. As the application of band saw cutting becomes increasingly popular, there is a growing demand for cutting performance, which makes it necessary to study saw teeth in order to improve efficiency and reduce processing costs.
To meet this demand, a study was conducted on the saw teeth of bi-metal band saw blades, examining design, technology, and operation aspects. It was found that the tooth deflection angle during the separation process has a significant impact on the cutting performance. Static analysis of spring steel showed that deformation of the back material in the feed direction is much smaller than the cutting depth, which has little influence on cutting performance. Observing chips, it was found that the chip width of separated teeth is similar to that of non-separated teeth, indicating a step-like sawing effect.
Furthermore, a parametric modeling was performed, creating a bi-metal band saw blade model with different lead angles, rake angles, installation angles, and tooth pitch. Numerical simulations of the sawing process were conducted using the finite element software AdvantEdge, and the effectiveness of the simulation was verified by experiments.
Based on single-factor and orthogonal experiment schemes, simulations were performed with different parameters, such as lead angles, rake angles, installation angles, and tooth pitch, to determine their effects on cutting force and chip radius. Single-factor experiments showed that the main factors influencing cutting force and chip radius were tooth pitch and installation angle, followed by lead angle and rake angle. Therefore, an empirical formula for cutting force based on tooth shape parameters was established, and a genetic algorithm NSGA-ii was used to optimize the tooth shape. The optimal tooth shape was determined to be a lead angle of 10°, rake angle of 30.01°, installation angle of 9.99°, and tooth pitch of 0.68mm. The research results showed that the optimized tooth shape reduced experimental costs and established the best design standards for tooth shape optimization of bi-metal band saw blades, providing a foundation for future studies on the cutting principles of bi-metal band saw blades.
In summary, the study on saw teeth of bi-metal band saw blades provided insights into improving efficiency and reducing processing costs, laying the groundwork for further research and development in the field.
