Fabricated Products Group, a manufacturer of architectural assemblies and components, relies on saws to cut material to length before it undergoes further fabricating and machining processes.
The sawing operation is important in some parts of the fabrication world because it is usually the first step in nearly all projects. Whether they are using a compound miter saw, a radial arm saw, or a table saw, most shops turn to the saw because it is the easiest way to bring material to the desired length and typically the most efficient way to cut material.
At Fabricated Products Group, we cut primarily aluminum from 1/8 to 2 in. thick. Circular saws are used most often, but band saws also are used for the occasional job. The horizontal band saw is used mostly to cut steel. The vertical saw is used for custom cuts and ripping material down to a specific size for those hot jobs.
With saws playing such an important role in a fabricating shop, the saw operators and maintenance team have to take steps to ensure the equipment is in pristine shape. If a saw is not functioning properly, the operator is at risk of injury. Malfunctioning saws also can produce undesired results, such as material being cut to the wrong length or out of square. As a result, the material becomes unusable or possibly scrap metal, and the operator must rework the project, which can be costly.
If a fab shop wants to improve its sawing operations, it can approach the task from multiple angles. One is through maintenance. A well-maintained saw is safe and efficient. A maintenance schedule usually is provided by the manufacturer. The monthly, weekly, or even daily maintenance schedules should be followed per the manufacturer’s recommendations to ensure proper saw performance and extend the life of the saw blades.
Fabricated Products Group has its operators perform the daily maintenance chores. Before using the saw, the operator checks the oil, the blade sharpness, and the blade’s squareness to the workpiece. The operator also checks to see if the saw is set up correctly with the right saw blade. Although most of the cutting jobs involve aluminum and saw operators can use the same blades for most of those jobs, they might need to change out the blade for a specialty job, such as one on which a thicker kerf is required. Monthly maintenance tasks are usually shared by operators and maintenance personnel.
Keeping a saw clean is crucial for proper saw maintenance. Over time, resins from oil and wax lubricants build up on the saw blade’s teeth. (If blade lubricant isn’t used, the metal can build up on the teeth and negatively affect cutting performance.) The resin effectively coats the edges, making the blade act as though it is dull. This leads to an increase in friction and heat, making cutting more difficult and resulting in cut edges that are not as clean as they could be.
While it may seem counterintuitive, a dull blade is more dangerous than a sharp blade because it requires more force to make the cut. As an operator is trying to force the dull blade into the metal, his hand is more likely to slip off the handle because of the increased force being applied. Blades that cut at maximum efficiency also reduce the strain on a saw’s motor.
Dull blades also can lead to quality issues. A dull blade tends to wander during the cut, not producing a straight edge like a clean blade does.
It is also important to properly lubricate the saw’s moving components per the manufacturer’s specifications. After each use, it is beneficial to lubricate blades with paste wax or lubricant. Lubricant can be rubbed on with a rag and left on the blade. Paste wax, however, should be wiped off after soaking into the blade for approximately 10 minutes. Both wax and lubricant assist in keeping rust off a saw blade. Removing the drive belt and motor from the back of the saw on some models, such as table saws, can dramatically improve access to the saw’s interior for cleaning and lubrication.
When staff members are properly trained on how to use a saw, the machine works safely and efficiently, producing strong results. For larger and more complex saws, such as those with digital readouts for positioning, dual cutting heads, and automatic feeds, the manufacturer usually offers training with the saw purchase, plus additional training to new employees at a cost. Trade schools also provide a great foundation for basic saw operation.
Two operators wear safety glasses, form-fitting gloves, and ear protection before engaging a saw.
However, most training is on the job with a senior fabricator with experience on the saw. Learning from industry veterans can help prevent injuries with employees new to the machine. It also can improve efficiency. For example, an experienced operator can recognize when improper cutting speeds are being used on a particular type or thickness of metal.
Learning from established co-workers encourages the staff to utilize best practices learned over the years. Less experienced saw operators also get to see how their more experienced counterparts deal with unexpected challenges, such as delaying a job because the saw blade lacks the proper amount of lubrication. They learn not only how to run the equipment, but also when not to run the equipment.
When using a saw, an operator needs to have the proper personal protective equipment (PPE). It is important for the employee to wear safety glasses with side shields or full-face shields to protect the eyes and the face and a leather apron to protect the body. It is ideal to avoid wearing loose-fitting clothing and gloves while operating a saw as they can get caught during the cutting process.
It is best to operate the blade at speeds recommended by the manufacturer. Anything outside of those parameters can lead to unexpected and potentially dangerous results. It also is recommended to use only the accessories designed for that specific saw and application. Doing otherwise could damage the saw.
Any adjustments should be secure before making a cut. These adjustments should be made only when the power is off and the machine is idle. It also is a safe practice to turn off the saw and place the material to be cut against the stop gauge when taking measurements. These steps are recommended not only for the health and safety of the operator, but also to protect the functionality and life of the machine and blades.
It is also helpful to optimize a cut list. This ensures the saw operator is getting the most out of the materials on hand and can cut everything on the list. At Fabricated Products Group, the project manager provides the cut list, which helps to ensure that enough of the right material is present for the job. The operator checks the cut list and proceeds in running the jobs in the most logical way. For example, if many small pieces are cut out of one large piece of raw material, the operator might not have enough material to cut a long piece on the cut list. In this scenario, it typically works best to go in the order of largest to smallest on the cut list.
No matter how precise the operator tries to be, discrepancies can sneak in during a project. When this occurs, parts need to be fitted into the job as the project moves along.
Used correctly, a cut list can be helpful in layout, confirming key dimensions, and estimating material needs. It also can indicate the order of construction and serve as a record of the build should the project need to be replicated, although that is rare in the custom fabrication industry.
An operator always needs to make certain the saw blade being used is suitable for the type of material to be cut as well as the type of cut to be made. Thinner blades that have more teeth are better-suited for making scroll cuts and tight turns, and they are best used with thinner material. Wider blades with fewer teeth are good for making rough cuts and cutting thicker material.
It is helpful to make sure the saw blade has been set to the proper tension before using it and that it is checked periodically and the tension readjusted whenever needed. Spotting damage to the blade before cutting commences can avoid real trouble, which means the operator should look for bent sections in the saw blade, broken teeth, or other damage. Our saw operators check saw blades at least once a shift. If the quality of a cut starts to deteriorate, the operator stops the equipment and checks the blade again, making any changes that might be necessary to improve the cutting action.
Maintenance, best practices, and training can boost a fabricator’s saw operation, leading to time and money savings on the front end of a project. They also protect the health and safety of those operating the machine, which is even more important than the machine’s output.
Senior Manufacturing Engineer
Fabricated Products Group
21950 S. La Grange Rd.
Frankfort, IL 60423
815-270-8010
See More by Russell Enzenbacher
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