friction saw blade

ERW Karbon Çelik Boru Fabrikası

Tube Mill Machine Compose

Soğuk Haddeleme Şekillendirme Makinesi

Çelik Rulo Kesme Hattı

Karbon Çelik Rulo Kesme Hattı

Çelik Rulo Boy Kesme Hattı

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friction saw blade

Friction Saw Blade is a specialized saw blade designed for high-speed, high-temperature hot cutting of metals. By utilizing the friction heat generated by high-speed rotation, the blade softens the metal surface and achieves fast cutting through frictional force. It is widely used in the steel industry, rolling mill cold beds, pipe mills, rebar processing plants, and structural steel cutting in heavy industrial applications.

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Key Features

High-Efficiency Hot Cutting: Utilizes friction heat generated by high-speed rotation to soften metal quickly and achieve high-speed cutting.
Special Heat-Resistant Steel: Made of special alloy steel with excellent heat resistance, ensuring stable performance under prolonged high-speed operation.
Optimized Tooth Design: Scientifically designed tooth geometry improves cutting efficiency and surface quality, reducing burrs and cracks.
High Toughness Welding Technology: Teeth are welded to the body using high-strength welding technology, ensuring safety and durability under heavy load conditions.
Excellent Dynamic Balance: Provides superior balance for stable high-speed cutting, reducing equipment load and vibration.

Main Applications

Steel mills and rolling mill cold bed shearing
On-line flying saw hot cutting in pipe mills
Fast cutting of structural steel, plates, and rebar
Primary processing of large castings, billets, and bars

2. BASIC Technical DATA

Item	Specification Range	Description
Malzeme	High-strength alloy steel	Heat-resistant, wear-resistant
Outer Diameter	Ø 300 mm - Ø 1600 mm	Customizable
Kalınlık	3 mm - 10 mm	Select according to application
Bore Size	Customized per customer needs	Standard or non-standard
Number of Teeth	Customized	Optimized tooth design for different conditions
Surface Hardness	HRC 45-52	Ensures wear resistance of teeth and toughness of body
Recommended Cutting Speed	60 m/s - 150 m/s	Adjust according to material, equipment, and process
Recommended Materials	Carbon steel, alloy steel, cast iron	Suitable for high-temperature, high-speed cutting

3. Friction Saw Selection Guide

Comparison Table: Friction Saw Blade vs. HSS Saw Blade vs. TCT Saw Blade

Item	Friction Saw Blade	HSS Saw Blade	TCT Saw Blade
Cutting Method	High-speed friction hot cutting	Cold-state mechanical cutting	Cold-state mechanical cutting
Recommended Cutting Speed	High (60-150 m/s)	Medium (40-80 m/s)	Low to medium (30-80 m/s)
Applicable Materials	Steel pipes, structural steel, rebar, alloy steel, cast iron	Carbon steel, stainless steel, alloy steel (thin materials)	Carbon steel, stainless steel, non-ferrous metals, composite materials
Service Life	Moderate	Long	Long
Cutting Efficiency	Extremely high	Medium	High
Cutting Surface Quality	Moderate, may require secondary processing (burrs, oxidation layer)	Smooth, minimal burrs	Smooth, minimal burrs
Cost Performance	Low cost, suitable for mass production and high-efficiency cutting	Relatively high cost	High cost
Suitable for Hot Cutting	Yes	No	No
Suitable for High-Speed Equipment	Yes (flying saws, cold bed shears)	No	No
Common Applications	Rolling mill cold beds, pipe mill flying saws, rebar processing	Metal profile cutting, machinery manufacturing	Precision cutting, aluminum profiles, window & door industry

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

SERTİFİKAMIZ Read More About cold cutting saw

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friction saw blade FAQs

1. What is a Friction Saw Blade?

A Friction Saw Blade is a specialized circular saw blade used for high-speed, high-temperature cutting of metals. It operates by generating frictional heat through high-speed rotation, softening the material at the cutting point, and enabling fast separation.

2. What materials can be cut with a Friction Saw Blade?

Friction saw blades are mainly used for cutting: Carbon steel Alloy steel Cast iron Steel pipes, profiles, billets, slabs, and rebar

3. What are the key benefits of using Friction Saw Blades?

Extremely fast cutting speeds High productivity for continuous or batch cutting Lower cutting cost compared to cold cutting methods Effective for hot cutting of large cross-section materials

4. What is the recommended cutting speed for Friction Saw Blades?

The typical recommended cutting speed is: 60 - 150 m/s at the blade's outer periphery This varies depending on the material type, thickness, and cutting equipment.

5. Can Friction Saw Blades be resharpened?

No. Due to the severe wear, deformation, and tooth geometry degradation during high-speed friction cutting, friction saw blades are typically non-resharpenable and should be replaced when worn.

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