Sawing processes explained
A closer look at the circular sawing machine
Even after 85 years, Bewo continues to work every day on further developing and perfecting the techniques behind tube cutting. With the advent of new technologies, continuous improvement remains possible. Faster, more accurate, more reliable and more economical – thanks, amongst other things, to reduced wear on the saw blades.
Bundle loader
Pipes and other profiles can be loaded into the machine as a complete bundle. The challenge lies in separating the pipes so that they can be fed to the saw one by one. Thanks to the interplay between the hopper movement and the feed chain, pipes can be processed fully automatically.
Thanks to years of development of the control software, it is possible to cut tubes from Ø 6 mm (known in the trade as ‘spaghetti’) without any problems.
Gripper-Tongs Feeding System
In the past, tubes were fed into the saw using a roller system, but we have now switched entirely to a gripper system. This reduces the risk of malfunctions, as a stop or guide is no longer required.
The gripper’s speed and accuracy are unrivalled: a speed of 4 m/s and an accuracy of 0.01 mm, controlled by a servo motor.
Proportional sawing
A cutting profile is generated based on the shape of the tube. This cutting profile is tailored to the geometry of the tube. As the saw blade moves through the tube(s), both the blade speed and the feed rate are continuously adjusted to achieve an optimal speed whilst minimising wear on the saw blade.
Even at full speed, the servomotor’s CPU continuously monitors and regulates optimal operation.
Saw Blade Management System
The saw blade is electronically divided into different sectors. By monitoring where the blade makes contact with the product, even minor deviations in the saw blade can be compensated for. This enables a finished product tolerance of < 0.1 mm and helps to minimise wear on the saw blade.
Cutting Wizard – Parameter generator
A sawing machine is fitted with dozens of sensors, and there are countless variables and parameters that can be adjusted to determine the correct cutting programme. To enhance ease of use, we have developed the Cutting Wizard software.
Based on the product characteristics and the type of machine, the best set of settings is generated automatically. The operator simply needs to fine-tune these for the best result. The settings can be saved, making it easy to switch between products and ensuring optimal production at all times.
Circular saw or tube laser?
A tube laser can cut out special shapes, which can be useful when a wide variety of products need to be manufactured.
A circular saw always makes a straight cut. If necessary, a further operation can then be carried out, such as notching, punching or end-forming. This is usually done for larger volumes, as the operation has to be set up for each individual product. A laser can customise each product differently by adjusting the software.
A circular saw is unrivalled when it comes to output and cost per cut. As the latest machines can be easily and automatically adjusted, this is also an effective solution for small batches.
In an industrial setting, opting for a circular saw makes sense, given the investment, running costs and maintenance involved. This is particularly important when the machine forms a strategic part of the production process.
