BEHRINGER introduced the HBM800ALU high-performance bandsaw for high-speed cutting of aluminum and other nonferrous materials, with fully automatic features and complete cutting capability that uses bi-metal or carbide-tipped saw blades. After loading stock, the machine continually manages all aspects of the process and provides real-time cutting data that is displayed at the operator terminal.
"To my knowledge, the new HBM800ALU bandsaw cuts aluminum faster than any other bandsawing machine,” according to Behringer president Richard Kipp, “and if you compare the overall costs to other types of saws — particularly to circular saws — then you immediately see the cost-effectiveness."
The HBM800ALU saw uses a 30-hp motor, whereas most circular saws with the same cutting range capability require a more expensive 100-150 hp motor.
"Blade cost," Kipp continued, "is also an area where customers can save. The 1.25-inch HBM800ALU blade is comparatively inexpensive to a circular saw blade, especially when cutting larger materials."
The new saw offers numerous features for efficiency and cost-effectiveness, and readily handles material sizes of up to 31.4-in. diameter round and 31.4 x 31.4-in. square. Like its predecessor, the HBM540A bandsaw, the new HBM800ALU features high drive output levels and fast cutting speed capability to meet the performance, precision and cut quality standards associated with aluminum cutting.
The machine's electronic control system contains several programmable functions engineered for efficiency. For example, the saw blade speed and feed rates are ramped up after initial penetration and ramped down as the blade exits the material. This prevents damage to the blade by assuring that the entry and exit of the aluminum is controlled and accurate.
The HBM800ALU’s frame has a cast iron construction that reduces vibrations and enhances torsion resistance during cutting. This provides higher band tensioning and precision movement, delivering flat cuts and tight tolerances. The saw-blade downfeed is driven by a precision ball-screw. Precise control of the blade to the material allows very high downfeed rates to be achieved and at the same time maximizes blade life. The servo drives also allow rapid positioning of the axis, reducing non-cutting cycle times.
Blade downfeed power and blade pressure are continually monitored and the servo-controlled cutting-pressure sensing system, which balances power and pressure, analyzes this data, and makes precise adjustments. This assures that the material feed rate is always maximized without overloading the blade.
Improved material usage and efficiency is realized in part because of the HBM800ALU’s narrow kerf (0.042 in.) Circular saws capable of fast cutting of large aluminum stock can leave a kerf up to four times as wide which, over a short period of time, wastes material. The narrow kerf minimizes lost material.
Driven by a frequency-controlled servo drive, the HBM800ALU feed gripper is mounted on linear guides to provide smooth transport of aluminum stock and further contributes to the fast cycle times. The machine also handles uneven stock, bundled material, or heavy forgings. The gripper clamping jaws automatically adjust to accommodate material width. Because the gripper may be positioned very close to the saw blade, remnant lengths are generally shorter by as much as 50% compared to other automated sawing centers.
Specially designed, low-friction blade rollers guide the high-speed saw blade while two self-adjusting brushes continually clean the blade. Chips are guided through the large funnel shaped saw base and fall into a large capacity conveyor system for removal. The machine features large hinged doors that provide complete access for cleaning and maintenance work such as changing the saw blade. Blade changing is done with a hydraulic blade-tensioning system.