Chip Brush

Optimal band saw chip brush positioning depends on machine configuration and chip formation characteristics. The most common and effective location places the brush immediately after the cutting zone where the blade exits the workpiece and begins traveling toward the upper wheel. This position cleans chips from gullets while they remain relatively loose, before centrifugal force can pack them during wheel passage. For horizontal band saws, mount the brush on the outfeed side where gravity assists chip removal. The brush should contact the blade back edge and extend into the gullet area without contacting tooth tips, which would cause premature brush wear and potential tooth damage. Adjust band saw chip brush pressure so bristles deflect slightly against the blade; excessive pressure creates unnecessary friction and accelerates both brush and blade wear, while insufficient pressure allows chips to pass uncleaned. Some heavy-duty applications benefit from dual brush systems with secondary brushes positioned near the drive wheel to remove any remaining debris.

Band saw chip brush bristle selection balances cleaning effectiveness, durability, and blade compatibility considerations. Synthetic bristles made from nylon or polyester compounds offer excellent resistance to cutting fluids, maintain stiffness across temperature ranges, and provide consistent performance in wet cutting environments. For general metal cutting with flood coolant, medium-stiffness nylon bristles between 0.010-0.020 inches in diameter deliver effective cleaning without excessive blade wear. Harder materials like stainless steel chips may require stiffer synthetic bristles or wire bristles for adequate removal force. Natural bristle materials like tampico fiber work well for softer materials like aluminum where aggressive cleaning is unnecessary. Wire bristles, either brass or steel, provide maximum cleaning power for stubborn chip accumulation but wear blade surfaces more rapidly than band saw chip brush assemblies using synthetic materials. Replace bristles when they compress permanently or show visible wear that reduces cleaning contact with blade gullets.

Band saw chip brush maintenance directly influences cutting efficiency through its impact on chip evacuation and blade condition. A properly maintained brush keeps gullets clean, allowing each tooth to cut at designed chip load without obstruction. This translates to consistent cutting rates, predictable blade life, and reliable surface finish quality. Neglected brushes with worn bristles permit chip accumulation that progressively degrades performance; operators may notice declining cutting speed, increased cutting force requirements, and premature blade dulling. Systematic band saw chip brush inspection should occur weekly in production environments, checking for flattened bristles, broken bristle sections, and proper blade contact pressure. Verify brush positioning has not shifted due to vibration or mounting bracket wear. Clean accumulated chips from brush holder assemblies that can prevent effective bristle contact. Schedule brush replacement based on bristle condition rather than fixed time intervals, as brush life varies with material characteristics and cutting intensity. Proactive band saw chip brush maintenance prevents costly blade failures and maintains optimal production throughput.