Friction Saw Cutoff Machine for ERW Tube Mill | High Precision, Efficient Metal Cutting

ERW јаглероден челик цевки мелница

Tube Mill Machine Compose

Машина за формирање на ладна ролна

Линија за сечење на челични намотки

Јаглероден челик серпентина за сечење линија

Челична калем пресечена до линијата за должина

Помошна опрема и резервни делови

Friction Flying Saw Machine

The friction saw is an online flying cutting system that uses high-speed rotating HSS blades to generate heat through friction, enabling efficient hot cutting of steel pipes. It is especially suitable for continuous production of carbon steel pipes, offering high-speed performance with relatively low operating cost. Compared to cold saws, friction saws are ideal for medium-to-large diameter pipes with moderate wall thickness.

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2. ОСНОВНИ ПОДАТОЦИ ЗА ДИЗАЈН

Дизајнот на предложената линија се заснова на следната спецификација:

Parameter	Specification
Applicable Pipe Diameter	Φ12.7mm – Φ406mm
Applicable Wall Thickness	0.5mm – 16.0mm
Saw Blade Diameter	Ø600mm – Ø1600mm
Main Motor Power	55kW – 160kW (variable frequency drive)
Max Cutting Speed	60 – 120 m/min (synchronized with line speed)
Cutting Length Range	4 – 12 meters (adjustable)
Length Tolerance	±3mm
Blade Cooling Method	Air cooling with optional nozzle blowers
Control System	PLC + HMI + Servo tracking system
Cutting Type	Single-blade (standard) or dual-blade (optional)
Saw Blade Type	65Mn , 8CrV type

3. Friction Saw Selection Guide

Item	Recommended Range	Notes
Pipe Diameter Range	Φ12.7 – Φ406mm	Match blade size with max pipe size
Max Wall Thickness	≤16.0mm (Carbon Steel)	Best for structural/general-purpose pipes
Blade Diameter Options	300mm/600mm / 800mm / 1000mm / 1250mm / 1600mm	Larger pipes require larger blades
Main Motor Power Range	55 – 160 kW	Depends on pipe size and cutting load
Line Cutting Speed	80 – 120 m/min	Works with servo-driven tracking system
Pipe Clamping	Pneumatic or hydraulic (double-sided)	Ensures stable cutting at high speed
Structure Type	Single blade (standard) / Dual blade (for heavy pipe)	Dual blade recommended for thick-wall pipes

4. Friction Saw vs. Cold Saw – Comparison Chart

Category	🟠 Friction Saw	🔵 Cold Saw
Cutting Principle	High-speed frictional heating and hot cutting	Low-speed, high-torque mechanical cutting
Blade Type	HSS (High-Speed Steel) friction blade	TCT / HM (Tungsten Carbide Tipped / Carbide) blade
Suitable Materials	Carbon steel	Carbon steel, stainless steel, alloy steel
Cutting Speed	Fast (60–120 m/min)	Medium (≤40 m/min)
Cutting Precision	±3mm (standard)	±1mm or better (high-precision)
Thermal Effect	Moderate (visible heat-affected zone)	Minimal (smooth, clean edges)
Burr & Surface Quality	May require post-processing	Excellent; minimal finishing required
Blade Life	Shorter (200–600 cuts/blade)	Longer (1000–2000+ cuts/blade)
Investment Cost	Lower (machine + blade cost)	Higher (machine + blade cost)
Best Applications	Structural pipes, scaffolding, fluid tubes	Automotive tubing, precision pipe, export-grade pipe
Not Recommended For	Stainless / high-alloy / ultra-thick steel	Extremely thick carbon steel (>10mm)

5. Conclusion & Recommendations

The flying friction saw is ideal for high-speed, continuous production of carbon steel tubes with moderate wall thickness and standard cutting tolerance.
For precision cutting, or when working with stainless steel or alloy steel, the cold saw provides better finish and dimensional control, although at a higher cost.
For flexible and cost-effective tube mills, many manufacturers choose a dual-system configuration—friction saw for general cutting, and cold saw for special grades or high-precision tubes.

6. Common Issues & Solutions – Flying Friction Saw for ERW Tube Mill

Issue	Possible Cause	Recommended Solution
1. Pipe ends have large burrs	• Blade is worn or blunt • Cutting speed too low • Incorrect blade angle	✔ Replace or resharpen the blade ✔ Increase blade RPM ✔ Check and correct blade angle
2. Pipe cut is not straight (angled cut)	• Clamping pressure is uneven • Blade deflection • Servo tracking delay	✔ Adjust clamping force ✔ Check blade stiffness and runout ✔ Recalibrate tracking system
3. Blade breaks frequently	• Excessive feed rate • Blade quality too low • Poor blade cooling	✔ Reduce feed rate ✔ Use high-quality friction blades ✔ Improve airflow or cooling
4. Blade overheating or discoloration	• Insufficient cooling • Cutting pressure too high • Blade too dull	✔ Enhance air cooling ✔ Reduce feed force ✔ Replace dull blades promptly
5. Cutting length tolerance is unstable	• Tracking system not properly synchronized • Servo encoder error	✔ Check servo encoder calibration ✔ Synchronize tracking mechanism with line speed
6. Sparks too intense or irregular	• Blade-to-pipe contact angle incorrect • Blade not aligned with pipe center	✔ Reposition blade and realign cutting unit ✔ Adjust inclination for optimal contact
7. Abnormal vibration or noise during cutting	• Blade imbalance • Loose bearings or guide rails • Pipe not clamped tightly	✔ Balance the blade ✔ Check all mechanical fastening points ✔ Reinforce pipe clamping
8. Blade wear is uneven	• Pipe not perpendicular to blade • Inconsistent clamping or feed speed	✔ Adjust blade angle ✔ Ensure stable pipe feeding and holding

🛠️ Maintenance Tips:

🕑 Inspect the blade daily for cracks, dull teeth, and heat spots
🔩 Tighten mechanical connections weekly (clamps, bearings, guides)
💨 Check cooling system air ducts and nozzles regularly to avoid clogging
⚙️ Recalibrate servo tracking every 500 hours or when pipe length deviation exceeds tolerance
🧰 Keep spare blades and wear parts (bearings, belts) in inventory to reduce downtime

НАШИОТ СЕРТИФИКАТ

Flying Friction Saw FAQs

1. Pipe ends have large burrs

✔ Replace or resharpen the blade ✔ Increase blade RPM ✔ Check and correct blade angle

2. Pipe cut is not straight (angled cut)

✔ Adjust clamping force ✔ Check blade stiffness and runout ✔ Recalibrate tracking system

3. Blade breaks frequently

✔ Reduce feed rate ✔ Use high-quality friction blades ✔ Improve airflow or cooling

4. Blade overheating or discoloration

✔ Enhance air cooling ✔ Reduce feed force ✔ Replace dull blades promptly

5. Cutting length tolerance is unstable

✔ Check servo encoder calibration ✔ Synchronize tracking mechanism with line speed

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