Sawing, Broaching &

Filing

Lecture Video
Sawing
Types of Saws
Power Hacksaw
Circular Saw (Cold Cut-off Saw)
Bandsaw
● Horizontal
● Vertical
Abrasive Chop Saw
Power Hacksaw
Power Hacksaw (Advantages)
Low capital investment
But accessories can add up quickly
Easy to set up
Simple operation
Low tooling costs
Simple design – easy maintenance
Versatile
Fair to good accuracy
Power Hacksaw (Disadvantages)
Slow
Noncontinuous motion
Reciprocating action
No blade support near actual cut
May cause bowing, inaccuracy
Blade wear is uneven
Circular Saw (Cold Cut-off Saw)
Circular Saw (Advantages)
● High Production Rate
● High Accuracy
● Fast Changeovers
● Burr-free Surfaces Possible
● Low Tooling Cost
● Low Operating Costs
● Relatively Safe
Circular Saw (Disadvantages)
● Higher Capital Investment
● Higher Horsepower Required
● Saw blades more expensive, but can be
re-sharpened.
● Size of stock that can be cut is small (14
inch blade can cut 4.25 stock)
● Greater loss of material (kerf width)
Horizontal Bandsaw
Horizontal Bandsaws
Scissors/pivot type (smaller, less expensive)
Post, dual column type
Horizontal Bandsaws (Advantages)
Rapid cutting
Safe and easy operation
Raw material savings
Low cost
Can be automated
Energy requirements lower (smaller kerf)
Disadvantages:
Less precise than circular saw
More floor space required
Vertical Bandsaws

Vertical Tilt-Frame
Bandsaw
Vertical Bandsaw (Advantages)
Versatility
Conventional sawing
Friction sawing
Diamond-band machining
Band filing
Band Polishing
Scallop-edge, wavy-edge, knife-edge sawing
Spiral Band sawing (omnidirectional cutting)
Abrasive wire band sawing
Vertical Bandsaw Operations
Contour Cutting
Slotting
3D Cutting
Stack Cutting
Shaping
Ripping
Slabbing
Abrasive Chop Saw
Advantages
● Fast
● Clean cut (with burr)
● Versatile
● Inexpensive
Disadvantages
● Heat
● Sparks
● Mess
Saw Blade Geometry
Tooth Spacing or Pitch
Distance between teeth
or teeth per inch (TPI)
Tooth Geometry
Tooth Set
Blade Thickness
Kerf Width

Note: New saw blades should be broken in gradually.

Saw Blade Geometry
Blade Geometry & Sawing Action
Saw Blade Set
Blade Width (bandsawing)
Blade width affects the smallest radius that can
be cut. Smaller blade allows more detail
(smaller radii). Larger blade width provides
more accurate straight cuts.
Broaching

Marc Lecuyer video:

Example (combination wrench)
 image: wikipedia.org

Broaching uses a tool with teeth whose depth of cut gets

deeper incrementally.
Advantages
High productivity rates
Close tolerances
Good Finishes
Economical Operation (for many applications)
Broaching
Disadvantages
● Only certain workpieces are suitable
● There cannot be any obstruction in the path
of the tool.
● Tapered holes cannot be broached
● Parts must be able to withstand high thrust
force.
● Require rigid machines and workholding
Broaching Machines
Vertical Surface
Vertical Internal Pushdown
Pullup
Pulldown
Horizontal Internal
Horizontal Surface
Continuous/chain broaching machines
Broach Geometry
Spline Broach (Example)
“Broaching” on a Mill or Lathe
Slotting/Shaping head Production Machining Article
“Broaching on a Mill or Lathe
Another example:
Rotary Broaching
(Wobble Broaching)
Filing
Types of Files (by tooth geometry)
Single Cut Files
Evenly spaced parallel teeth
Double Cut Files
Two sets of teeth
Rasp-Cut
Individual teeth
(grades are bastard, cabinet and wood)
Vixen-Cut/Curved cut
Curved teeth, resist clogging
 File Terminology
Tang - the pointed part of the file that is inserted into the
file handle
Heel - the part of the file that comes next to the tang - also
known as the shoulder
Point - the end of the file opposite the tang
Length - the distance between the point and the heel -
also known as the body
Teeth - the cutting ridges on the file's surface
Side - the wide file surface - used for most filing
Edge - the narrow file surface - may be round or square in
shape
Back - the rounded side of all half-round files
Safe - refers to an edge or side with no teeth cut
American Pattern File Grades
Dead smooth
Smooth
Second
Bastard
Middle
See: KMS File Identification Chart for reference
Rough
The actual degree of roughness is proportional
to the length of the file.
Swiss Pattern File Grades
Swiss Pattern Files
Available in seven grades
00,0,1,2,3,4,5,6

Most coarse is 00, and degree of roughness is proportional

to the length of the file.

Swiss pattern files have different shapes

Swiss Pattern File Types and
Classes
I - Barrette XI - Pippin
III - Crochet XIII - Round
IV - Crossing Straight
V - Equalling Taper
VII - Hand XIV - Slitting
VIII - Joint (class 1-4) XV - Square
IX - Knife XVI - Three square
XI - Pillar XVII - Warding
Swiss Pattern File Types and
Classes
XVIII - Needle
XX - Diesinkers, Rifflers, Regular.
Round
Half Round Number 1-18
Three-Square XXI - Screwhead
Crossing With tang
Knife
Without Tang
Flat
Square XXII - Contact point
Barrette
Joint
Note: Both American pattern files and Swiss
Equalling
pattern files are called “engineer’s files)
Slitting
Marking
Filing Techniques
Cross Filing &
Draw filing
Filing Technique
Keep level, and apply light even pressure on both sides
when draw filing.

Always use a handle when using with power equipment.

Files should be kept clean with a file card. Scrape along

the teeth.
Rotary Burrs
Have standard identification system see
Bahco p. 40 for reference
Die Filers, Band Files

Die filer to make square hole 1:06

See Also
Hand Scraping
and flaking

http://en.wikipedia.org/wiki/Hand_scraper#mediaviewer/File:ScrapingPatternSlideway.jpg
Broach Example
Surgical Instrument
Return to Slide 15