Circular Saw Manufacturing Process

What is a Circular Saw ?

A circular saw, often known as a buzz saw, is a power tool that uses a toothed or abrasive disc or blade to cut various materials in a rotating motion while spinning around an arbor. A hole saw and a ring saw both employ a rotating motion, but they vary from a circular saw.

Circular Saw Manufacturing Process

13 Steps Circular Saw Manufacturing Process

Material Selection For Circular Saw Manufacturing Process

1.Material Selection: The procedure begins with determining the best material to ensure the blade’s longevity and efficacy. High-speed steel (HSS) is preferred for its hardness and tolerance to high temperatures, making it excellent for high-speed cutting. Carbide-tipped materials are used because they are extremely robust and wear resistant, making them ideal for cutting tougher materials. Diamond-tipped blades are utilized for the most abrasive materials and provide unsurpassed durability.

2.Blank Production: The blade begins as a metal blank that is created by forging or precise casting to generate a rough version of the saw blade. Forging includes heating the metal until it becomes pliable and then shaping it under pressure, which aligns the grain and increases strength. In contrast, precision casting is the process of pouring molten metal into a mold to achieve intricate forms with high accuracy. The blank is then laser cut to a precise diameter, maximizing material consumption and reducing waste.

Blank Production For Circular Saw Manufacturing Process
Heat Treatment For Circular Saw Manufacturing Process

3.Heat Treatment: This important phase includes heating the blank to a certain temperature and then rapidly cooling it, also known as quenching. This modifies the steel’s microstructure, resulting in increased hardness and durability. Tempering, a warming procedure that minimizes brittleness while retaining quenching hardness, may also be applied to the blade.

4.Tooth Formation & Sharpening: The saw teeth are methodically created by milling or grinding, with each tooth designed to operate optimum for the blade’s intended usage.Sharpening is honing the edges of each tooth to a razor sharp finish, ensuring that the blade cuts smoothly and effectively.

Tooth Formation & Sharpening For Circular Saw Manufacturing Process
Polishing and cleaning For Circular Saw Manufacturing Process

5.Surface Treatment: Coatings like titanium nitride (TiN) may dramatically reduce friction and wear on the blade, extending its life. These treatments help prevent corrosion, ensuring that the blade retains its functionality over time.

6.Tensioning and Leveling: Correct tensioning and leveling are critical to the blade’s performance. Tensioning is the process of applying pressures into a blade to maintain it flat and stable during operation. Leveling ensures that the blade is absolutely level, allowing for precise cuts while lowering the possibility of blade wobbling.

Tensioning and Leveling For Circular Saw Manufacturing Process
Brazing For Circular Saw Manufacturing Process

7.Brazing: Brazing is the process of melting a filler metal and flowing it into the connection between the carbide or diamond tips and the saw blade body to attach them. This process creates a strong, permanent connection that can endure the strains of cutting.

8.Polishing and cleaning: The blade, particularly around the carbide tips, is polished to eliminate brazing discolouration and provide a clean surface for best performance. Cleaning the blade, particularly the seating for the carbide tips, is critical to a successful brazing procedure.

Polishing and cleaning For Circular Saw Manufacturing Process
Grinding For Circular Saw Manufacturing Process

9.Grinding: The carbide tips are precision ground to provide the final cutting profile. This stage is particular to the kind of saw blade and its uses, influencing the blade’s cutting properties and performance.

10.Quality Control: Stringent quality control processes are in place to guarantee that each blade meets exacting requirements. This involves inspecting the blade’s balance, sharpness of the teeth, and general durability.

Quality Control For Circular Saw Manufacturing Process
Laser Marking For Circular Saw Manufacturing Process

11.Laser Marking: Laser marking creates a permanent mark on the blade that includes important information such as the blade type, size, manufacturing batch, and date. This phase provides traceability and quality assurance.

12.Packaging and delivery: The completed blades are carefully wrapped with protective materials to avoid damage during transit. The delivery procedure is adjusted depending on the order’s destination and size, resulting in efficient and safe conveyance to clients.

Packaging and delivery For Circular Saw Manufacturing Process

Circular Saw Manufacturing Process Video

Circular Saw Production Machine Line

Three-position milling machine

Three-position milling machine

Dual-face milling machine

Dual-face milling machine

Dual-head milling machine

Dual-head milling machine

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