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16
15.0 Troubleshooting
15.1 Blade and cutting problems
Problem Probable Cause Solution
Teeth breaking
Coolant flow problem
Ensure proper coolant flow; hoses unclogged; nozzles
pointed correctly, etc. Make sure coolant type is
suitable for the machine.
Material too hard
Check the blade speed and the type of blade you are
using. Also be aware of feed pressure.
Blade not worn-in correctly
With a new blade it is necessary to start cutting at half
feeding speed. After the wearing-in period (a cutting
surface of about 300 cm
2
for hard materials and about
1000 cm
2
for soft materials) the blade and feed speeds
can be brought up to normal values.
Blade with excessively fine
tooth pitch
The swarf wedges into the bottom of the teeth causing
excessive pressure on the teeth themselves. Use a
blade with coarser tooth pitch.
New blade inserted in a
partially completed cut
The surface of the cut may have undergone work
hardening. When starting work again, use a lower
blade speed and reduced feed pressure. A tooth from
the old blade may be left in the cut: check and remove
before starting work again.
Work piece not clamped firmly
in place
Any movement of the work piece during cutting can
cause broken teeth: check the vise, jaws and clamping
pressure.
Rapid tooth wear
Feed speed too slow
The blade runs over the material without removing it:
increase feed speed.
Blade speed too high
The teeth slide over the material without cutting it:
reduce the blade speed.
Insufficient coolant
Check the coolant level and clean coolant lines and
nozzles.
Incorrect fluid concentration Check and use the correct concentration.
Material defective
The materials may present altered zones either on the
surface, such as oxides or sand, or in section, such as
under-cooled inclusions. These zones, which are
much harder than the blade, cause the teeth to break:
Discard or clean these materials.
Broken blade
Blade speed too high Reduce blade speed.
Teeth in contact with material
before starting the cut
Always check the position of the blade before starting
a new job.
Insufficient coolant
Check the coolant level and clean coolant lines and
nozzles.
Cuts not straight Feed speed too strong Reduce feed speed.
Blade not perpendicular to
workpiece.
Contact Walter Meier technical support.
Table 5