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FAQ of KaiKong Flying Cold Saw
1.      What is flying cold saw?
The flying saw is used in the high frequency welding pipe production line, the welding pipe which produces continuously carries on the fixed length cutting equipment. The traditional flying saw adopts the principle of hot friction. When the high-speed rotating saw blade comes into contact with the steel pipe, high temperature will be generated due to friction, and the hardness of the pipe wall will decline due to high temperature. The sawtooth will then take away the semi-melted debris to achieve the purpose of cutting off the steel pipe. It is also known as a hot cutting saw or friction saw because of its high noise, dust and friction sparks.
Cold cutting saw is the name corresponding to the traditional hot cutting (friction) saw. It adopts the emerging cutting technology and the cutting process is similar to the milling principle. The specially processed cutting blade cuts the pipe wall at low rotation speed, and the saw blade feeds at a specific speed (controlling the amount of single-tooth milling) to cut the pipe wall. Because of the use of milling principle, cutting process cooling fluid cooling and lubrication, will not produce high temperature spark, so called cold cutting saw. Because the speed and feed of the cold cutting saw blade are strictly controlled, the steel pipe will not melt at high temperature during the milling process. Therefore, the pipe end cut by the cold cutting saw is flat and smooth without burr.

2.      What are the benefits of using cold cutting saw?
With the increasing maturity of cold cutting technology, the benefits of using flying cold saws are increasing. In our practice, our customers mainly focuses on the following aspects:
1)       no burr pipe, improve aesthetic. In the sales link, the downstream customers are more willing to purchase such pipes;
2)       The length accuracy is accurate, and the pipe end is smooth. The customer has made an estimate, saving the milling ends equipment costs, labor costs, waste material costs, 1~2 years can recover the cold flying cold saw investment;
3)       Traditional cutting saw blade rotation speed of 3000rpm, converted linear speed of 70~100 m/s, if the blade burst, debris impact is no less than the bullet, is a great safety hazard. Cold cutting saw blade speed low, and no dust and spark, reduce the fear of operators;
4)       Flying cold saw adopts digital servo flexible motion control, which has little impact on machinery. Mechanical design is more precise, with its own lubrication device, the actual use of the failure and maintenance is even less than the traditional friction saw. That’s drop done total cost of ownership

3.      What saw blade does the flying cold saw use? What is the life of the saw blade?
Two types of saw blades are available for cold cutting: high speed steel and tungsten carbide tipped. But the specific use of which saw blade, depends on the size and material of the pipe.
In general, high speed steel (HSS) saw blades are suitable for cutting structural steel or non-alloy tool steel whose tensile strength does not exceed 500MPa. Tungsten carbide tipped (TCT) saw blades are suitable for high hardness and high density alloy materials whose tensile strength is greater than 500MPa up to 1000MPa. High speed steel saw blades cannot withstand excessive cutting arc length, so tungsten carbide tipped saw blades are also used for pipes with thicker pipe walls. In practice, the speed and feed rate of high speed steel and alloy tooth saw blade are different.
The service life of the saw blade is also related to the size and material of the pipe, and is related to the design of the cutting machine, cutting time, grinding state, etc. The same saw blade using in different machine may have different life time.
1)       Mechanical design: when the saw blade is cut, the steel pipe shall be completely fixed without displacement. The output torque of the saw blade shall should be keep balanced;
2)       Cutting time: the shorter the cutting time (i.e. the greater load of single blade tooth), the greater damage of the blade and the shorter the blade life;
3)       Grinding status: the new factory saw blade has good coating intact, reasonable tooth shape, sharp ruler tip. But if the customer grinds the used blade, the blade grinding quality is often related to grinding equipment. Simple and low end grinding equipment generally can not be grinding into the factory quality shape. This will cause blade life decline after grinding.
If you want to know the service life of the saw blade, please inform us of the pipe specification, and we will calculate it for you.
The shape and number of teeth of the saw blade also affect the cutting effect.

4.      What is the cutting precision of your flying cold saw?
As mentioned above, the flying cold saw is fully controlled by digital servo motor. The control system collects the length signal of the steel pipe being cut, and the dragging servo tracks the cutting point according to the collection signal. Therefore, the cutting precision of the flying cold saw is significantly higher than that of the traditional friction saw. Under the condition that the undulation degree of the tube mill machine is not more than 2%, our company guarantees that the cutting accuracy is less than ±1.5mm, and the accuracy of over 80% can reach ±1mm. The cutting precision is independent of the cutting length.

5.      How much speed can your flying cold saw ?
The speed of the flying cold saw is determined by the type of flying saw and the specification of the pipe. The specification of the pipe (pipe diameter/wall thickness) determines the time of cutting. The longer the cutting time, the slower speed of the saw, and vice versa. Our company has a complete set of formulas to calculate the cutting time of a certain type of pipe, and then calculate the maximum speed of the flying saw, which requires knowing the material, shape and thickness of the pipe for specific analysis. The maximum speed of a particular pipe can be displayed on the touch screen of our control system.
KK - 5 cold flying saw cutting maximum speed of up to 130 m/min
KK - 5H high-speed cold cutting saws maximum speed of up to 150 m/min
For example: pipe type φ20mm, the thickness 1.4 mm, the carbon steel material, the actual production speed of our cold saw can reach 120 m/min.

6.      What size of pipe can your flying cold saw cut?
Kaikong brand flying cold saw includes kk-5 and kk-5H two series products. KK-5 is a common cold cutting saw with 9 types ranging from 20 to 165. The applicable pipe type parameters are shown in the following table:

Saw Type Diameter(mm) Thickness(mm) Max Speed(m/min)
KK-5-20 Φ6~25 0.3~1.2 130
KK-5-32 Φ8~38 0.3~2.0 120
KK-5-50 Φ20~63.5 0.6~2.5 110
KK-5-60 Φ25~76 0.8~2.5 90
KK-5-76 Φ25~89 0.8~3.5 90
KK-5-89 Φ38~105 0.8~4.0 80
KK-5-114 Φ48~114 0.8~4.0 70
KK-5-127 Φ50~140 1.2~5.0 60
KK-5-165 Φ76~168 2.0~6.0 60
Note①: Diameter of the circular pipe. Reference this value for other profile tube.
Note②: Mechanical design and blade diameter decided by Max Diameter/Max thickness.
Note③: Max speed of the saw running. The actual speed depends on pipe specification.

Kk-5H series is high speed flying cold saw with maximum pipe diameter of 50mm, maximum wall thickness of 1.2mm and maximum speed of 150m/min.

7.      What kind of daily maintenance is required for flying cold saw?
Flying cold saw is a precision electro-mechanical integration equipment, with guide rail, lead screw, gear rack and other precision parts, saw car movement speed, system vibration, water, gas, electricity, dust environment slightly bad, regular maintenance is conducive to making the equipment in good working condition. Regular maintenance mainly involves lubrication, removing sawdust, checking whether the screw fixed parts are loose, checking whether the water/electricity/gas/liquid loop is normal and so on. We have a detailed equipment maintenance manual which can be obtained from our company.

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