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Metal cutting band saw blade speed is related to feed rate and feed pressure, and customers often ask how to set up a bandsaw for the best cutting results. We have previously looked at installing and breaking in your metal cutting bandsaw blade, so here we’re going to look at how to get the best results by adjusting cutting speed.
Table of Contents
How to use a blade speed chart correctly
Blade speed charts provide guidance on the best speed for different metals and different profiles. Charts give you speed in either feet per minute (FPM) or meters per minute (M/Min) depending on the origin of your bandsaw, and are commonly included in your metal cutting bandsaw operators manual.
FPM is the standard in the USA, and M/Min is the standard in Europe and Asia. The blade speed chart is the first part of the process of adjusting the cutting characteristics of your metal cutting bandsaw. After setting blade speed you examine the chips produced while cutting to make adjustments to improve the quality of the cut.
Explainer: how does material profile affect blade speed and feed settings?
Let’s consider the requirements for different material profiles. We know that thin wall tubing requires a finer blade than thicker materials, so you need to select a blade with higher TPI, but it also may require different blade speed and feed pressure to avoid tearing or distortion during cutting.
Safe starting speed for thin steel tube & steel angle
- 180-220 FPM
- 54-67 M/min
Starting with a comparatively low speed and low pressure is a good idea when working with thin wall tube, square, or angle profiles, but the only way to correctly set the speed for a specific profile is to look at the chips being generated and use those as a guide to changing the machine settings.
We’ll look at how we assess the chips being formed during cutting later, as this gives you immediate feedback on the quality of cutting. For now, just keep in mind that profile shape can have a significant impact on cutting speed and quality of cut, and the figures for materials are guidance based on square cuts through solid stock.
Blade speed chart
Refer to your machine manual to identify the closest available cutting speed for your machine and how to adjust the cutting speed. With a pulley driven machine you may need to change the pulley configuration, by moving the v-belt between different pulley combinations. With geared machines you may simply have to adjust the machine speed by a dial controller. The following chart is for dry cutting, if you are using lubricants the biggest effect is on feed rate, which can be increased up to 15%.
| Standard Materials | FPM | M/Min |
| Carbon Steel | 196-354 | 60-108 |
| Alloy Steel | 111-321 | 34-98 |
| Mold Steel | 246 | 75 |
| Stainless Steels | FPM | M/Min |
| Stainless Steel | 85 | 26 |
| Cr Stainless Steel | 85-203 | 26-62 |
| Free Machining Stainless Steel | 150-203 | 46-62 |
| Cast Irons | FPM | M/Min |
| Grey Cast Iron | 108-225 | 33-75 |
| Ductile Austenitic Cast Iron | 65-85 | 20-26 |
| Malleable Cast Iron | 321 | 98 |
| Tool Steels | FPM | M/Min |
| Tool Steel | 203 | 62 |
| High Speed Tool Steel | 75-118 | 25-36 |
| Cold Work Tool Steel | 95-213 | 29-65 |
| Hot Work Tool Steel | 203 | 62 |
| Oil-Hardened Tool Steel | 203-213 | 62-65 |
| Water-Hardened Tool Steel | 242 | 74 |
| Soft Materials | FPM | M/Min |
| Aluminum / Aluminum Alloy | 220-534 | 67-163 |
| Copper / Copper Alloy | 229-482 | 70-147 |
| Plastics / Wood | 220 | 67 |
Once you have set the metal cutting bandsaw blade speed, start cutting and observe the chips produced. The appearance of the chips is the best way to determine whether you need to increase or decrease the feed rate or blade speed to get the best results. The chip guide below the blade speed chart is a useful reference for you to use to make these adjustments.
How to read the metal chips that are being made by your bandsaw cuts
When you look at the chips being made as your bandsaw cuts through the material they give an indication of whether you need to adjust feed rate, pressure or blade speed or a combination of these to get the best results. Ideally, chips should be thin shavings of metal with a gently curled profile, as shown in the first entry on the chip chart below. Refer to the chart to see what adjustments you should try if your chips look different.
| Appearance | Description | Color | Blade Speed | Feed Rate | Other Issues |
|---|---|---|---|---|---|
 | Thin & curled | Silver | Good | Good | |
 | Thick, short & hard | Brown / Blue | Increase | Decrease | |
 | Hard, strong & short | Brown / Blue | Increase | Decrease | |
 | Hard, thick, strong & curled | Silver / Light Brown | Good | Decrease slowly | Check Blade Pitch |
 | Hard, coiled & thin | Silver | Increase | Decrease | Check Blade Pitch |
 | Straight & thin | Silver | Good | Increase | |
 | Powdery / Gritty | Silver | Decrease | Increase | |
 | Tightly coiled & thin | Silver | Good | Decrease | Check Blade Pitch |
The feed rate, or the speed at which the blade cuts through the workpiece, depends on blade type and feed pressure. Feed rate is usually controlled by a feed rate dial on the control panel, but there may be an adjustable spring to adjust feed pressure. Hydraulic feed saws will have specific controls for the hydraulic pressure. Refer to the operating manual to find the method of adjustment for your metal cutting bandsaw. In most cases, using lubrication enables the feed rate to be set about 15% higher than if dry cutting.
Rong Fu metal cutting bandsaws are easy to adjust for blade speed & feed rate
Contact us to discover the range of Rong Fu metal cutting bandsaws, all of which have features to make blade speed and feed rate easy to adjust for optimum cutting efficiency. Our portfolio ranges from the portable 6” manual RF150V through to the RF300 column saw with hydraulic controls. Whatever your metal cutting task, we have a bandsaw to match it.
