Making the blade last longer

Run-in the blade

In order to achieve good cutting performance and a long service life, it is necessary to first run-in the bandsaw blade to slightly round the cutting edges. Otherwise, there is a risk of extensive breakage of the tooth tips and thus a significant reduction in tool life.

  • Proper bandsaw blade run-in creates a stable cutting edge

    Proper bandsaw blade run-in creates a stable cutting edge

  • New tool with extremely small cutting edge roundness

    New tool with extremely small cutting edge roundness

  • Incorrect run-in will cause micro-cracks on the cutting edge

    Incorrect run-in will cause micro-cracks on the cutting edge

Follow these guidelines

  • By setting 75% cutting speed and 50% feed rate compared to the recommended values.
  • For large materials by cutting off approximately 500 cm².
  • For small materials for approximately 15 minutes.
  • When vibrating, by reducing the bandsaw blade speed again.

Speed chart for bimetal bandsaw blades

  • Aluminum, copper, brass
  • Free-cutting steels
  • Structural steels
  • Case-hardening steels
  • Bearing steels
  • Nitriding steels
  • High-speed steels
  • Stainless steels
Diameter (mm) Blade speed
(m/min)		 Feed rate
(mm/min)		 Recommended
tooth pitch		 Emulsion
(% of oil)
20-50 120 650-150 8-12 10-25
50-90 120-115 450-120 4-6
90-140 120-110 300-100 3-4
140-250 120-105 250-65 2-3
250-370 120-100 135-40 2-3
370-500 120-80 90-25 1,4-2
500-700 120-70 70-13 1,0-1,5
700-1000 120-60 50-6 0,75-1,25
Diameter (mm) Blade speed
(m/min)		 Feed rate
(mm/min)		 Recommended
tooth pitch		 Emulsion
(% of oil)
20-50 100 180-140 8-12 10-15
50-90 100 140-100 4-6
90-140 100-90 100-75 3-4
140-250 90-80 75-50 2-3
250-370 80-75 50-30 2-3
370-500 75-70 30-20 1,4-2
500-700 70-60 20-12 1,0-1,5
700-1000 60-45 10-7 0,75-1,25
Diameter (mm) Blade speed
(m/min)		 Feed rate
(mm/min)		 Recommended
tooth pitch		 Emulsion
(% of oil)
20-50 75 120-145 8-12 5-10
50-90 75-74 120-75 4-6
90-140 74-70 75-60 3-4
140-250 70-66 60-39 2-3
250-370 66-61 39-23 2-3
370-500 61-55 23-16 1,4-2
500-700 55-50 16-10 1,0-1,5
700-1000 50-40 10-6 0,75-1,25
Diameter (mm) Blade speed
(m/min)		 Feed rate
(mm/min)		 Recommended
tooth pitch		 Emulsion
(% of oil)
20-50 65-62 115-80 8-12 5-10
50-90 65-60 90-60 4-6
90-140 64-57 65-45 3-4
140-250 61-53 48-30 2-3
250-370 57-49 32-17 2-3
370-500 51-42 18-12 1,4-2
500-700 45-36 13-8 1,0-1,5
700-1000 40-28 9-5 0,75-1,25
Diameter (mm) Blade speed
(m/min)		 Feed rate
(mm/min)		 Recommended
tooth pitch		 Emulsion
(% of oil)
20-50 60-59 100-70 8-12 5
50-90 59-57 70-52 4-6
90-140 57-55 52-42 3-4
140-250 55-51 42-28 2-3
250-370 51-47 28-17 2-3
370-500 47-42 17-11 1,4-2
500-700 42-34 11-7 1,0-1,5
700-1000 34-26 7-5 0,75-1,25
Diameter (mm) Blade speed
(m/min)		 Feed rate
(mm/min)		 Recommended
tooth pitch		 Emulsion
(% of oil)
20-50 45-42 80-45 8-12 5
50-90 45-40 50-32 4-6
90-140 42-37 37-27 3-4
140-250 40-35 30-18 2-3
250-370 38-33 20-12 2-3
370-500 35-30 13-8 1,4-2
500-700 32-28 9-6 1,0-1,5
700-1000 30-23 6-4 0,75-1,25
Diameter (mm) Blade speed
(m/min)		 Feed rate
(mm/min)		 Recommended
tooth pitch		 Emulsion
(% of oil)
20-50 50 92-55 8-12 3
50-90 50-47 55-41 4-6
90-140 47-44 41-34 3-4
140-250 44-42 34-22 2-3
250-370 42-38 22-14 2-3
370-500 38-34 14-9 1,4-2
500-700 34-31 9-6 1,0-1,5
700-1000 31-25 6-4 0,75-1,25
Diameter (mm) Blade speed
(m/min)		 Feed rate
(mm/min)		 Recommended
tooth pitch		 Emulsion
(% of oil)
20-50 47-39 75-37 8-12 10-15
50-90 45-37 50-25 4-6
90-140 44-35 30-20 3-4
140-250 42-33 22-13 2-3
250-370 40-31 14-8 2-3
370-500 38-28 9-5 1,4-2
500-700 35-25 6-3 1,0-1,5
700-1000 32-21 4-2 0,75-1,25

The values given in the tables are referential for solid materials with a hardness of 20 HRC (225 HB). If you are cutting materials with a higher hardness, adjust the speed of the bandsaw blade as follows:

  • 25 HRC (250 HB): -15%
  • 30 HRC (277 HB): -25%
  • 35 HRC (322 HB): -35%
  • 40 HRC (373 HB): -45%

On pivotal band saws, reduce the feed rate by 20%. If you are using a different tooth pitch than the recommended one, reduce the feed rate by 15% with each step.

When dry cutting, reduce the cutting parameters by 30-50%.

Watch the chips

You can deduce the correctness of the cutting parameters by the chips ejected from the cut. The shape of the chip is affected by the selected tooth pitch, the speed of the bandsaw blade and also the feed. For most materials, thick and blue chips are bad, powder is unnecessary caution. Similarly, beware of heavily twisted chips, which can indicate a clogged gap and be the cause of a broken tooth.

  • Loose twisted chips - correct cutting values

    Loose twisted chips - correct cutting values

  • Thin or powdery chips - speed up the feed or reduce the blade speed

    Thin or powdery chips - speed up the feed or reduce the blade speed

  • Thick, heavy or blue chips - slow down the feed or increase the blade speed

    Thick, heavy or blue chips - slow down the feed or increase the blade speed

Blade service life

The life of a bandsaw blade is always affected by several factors. In addition to the choice of the blade, these include the design of the machine and its regular maintenance, the quality of the material to be cut, which may have inclusions or internal stresses, and last but not least the correct concentration of cutting fluid and the experience of the machine operator. For the best results, follow these recommendations:

Choose the right blade

  • Choose the right bandsaw blade for the material to be cut.
  • Keep the blade tension in the range of 250-300 N/mm². If you do not have a tensometer, our technician will take the measurements for you.
  • Run in new bandsaw blades.
  • As a general rule, never run a new tool into an old cut if the previous bandsaw blade has been destroyed.
Choose the right blade

Machining the material

  • Have the correct cutting parameters for the material being cut. Our technicians will be happy to help you with recommendations.
  • The chip shape helps you to fine-tune the cutting parameters.
  • Clamp the material properly in the vise. Above all, avoid rotation and vibration.
  • It is recommended to clamp or weld the material bundles at the other end.
Machining the material

Keep the machine in shape

  • Monitor wear and adjustment of the bandsaw blade guidance system.
  • Always check the functionality of chip brushes when changing the tool.
  • If chip brushes are not installed, provide more rinsing of the bandsaw blade behind the cut.
  • Always keep the guides set as close as possible to the material.
  • The distance between the back of the blade and the impeller flange should be constant at approx. 1 mm. If this is not the case, adjust the tilt of the driven wheel.
  • Ensure cleanliness and prescribed general maintenance of the machine.
Keep the machine in shape

Use quality cutting fluid

  • Use only high quality media that lubricates, cools and transports chips well.
  • Monitor the concentration of the cooling emulsion with a refractometer.
  • Ensure that the coolant is supplied to the cutting area under low pressure and in sufficient quantity.
  • Do not exceed the recommended lifetime of the media, as this reduces its effectiveness.
Use quality cutting fluid

Workplace safety

Please pay attention to your own safety. Wear protective equipment, be careful when unpacking, as the tension may suddenly release, keep the machine switched off when changing the bandsaw blade, remove the plastic tooth protection only after placing it on the impellers, keep all protective covers closed when cutting and never reach into the area of ​​the running machine.

  • Always wear protective equipment

    Always wear safety shoes, gloves, and protective eyewear when working

  • Always keep the teeth facing away from you

    Always check the bandsaw blade with the teeth facing away from you

  • The tied saw blades are tensioned

    Be careful when unpacking the bandsaw blades. The loops or bundles are under tension