Troubleshooting Common Issues of Iron Saw Blades: Causes and

Below is a concise breakdown of the three most common issues with iron saw blades, focusing on core causes and actionable solutions for quick troubleshooting.

1. Chipped Teeth

Core Causes

Sudden chipping: Cutting hard inclusions (weld spots, sand in cast iron), overly fast feed rate, eccentric blade installation, unstable workpiece clamping.

Gradual chipping: Tooth fatigue from repeated impact, blade overheating (softens edges), using iron blades for high-hardness materials (>250 HB).

Targeted Solutions

For sudden chipping:

Stop cutting, remove hard inclusions (grind weld spots, mark sand in cast iron).

Reduce feed rate to recommended range (e.g., 400–500 mm/min for Q235 steel with 300mm blade).

Reinstall blades with matched flanges (1/3–1/4 of blade diameter) and re-clamp workpieces tightly.

Replace blades if >3 teeth are chipped (chip size >1mm); smooth small chips (<0.5mm) with a 3mm grinding wheel.

For gradual chipping:

Test workpiece hardness—switch to carbide blades if >250 HB.

Upgrade cooling (dry → emulsion, 8% concentration, flow ≥15 L/min) to lower blade temp (<200°C).

Grind dull/fatigued teeth; replace blades if chipping spreads.

2. Rough Cuts (Burrs, Uneven Surfaces)

Core Causes

High roughness (Ra>6.3μm): Dull teeth, low rotational speed, sawdust-clogged tooth grooves, blade deformation.

Edge burrs/tears: Overly fast feed rate, wrong tooth angle (negative for soft steel), poor cooling, uneven clamping.

Targeted Solutions

For high surface roughness:

Sharpen teeth (800-grit diamond stone for slight dullness; grinder for severe wear).

Increase rotational speed (e.g., 1,800 rpm for 300mm blades cutting Q235 steel).

Blow out sawdust with compressed air (≤0.4MPa) every 5 cuts; straighten deformed blades (≤0.1mm deformation) or replace (＞0.2mm).

For edge burrs/tears:

Reduce feed rate by 20–30% (e.g., 700→500 mm/min for Q235 steel).

Use positive front angle blades (10°–15°) for soft steel; switch to oil mist cooling (8% concentration) to prevent adhesion.

Re-clamp workpieces with even pressure (no gaps >0.05mm); remove burrs with a scraper or pneumatic tool.