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Band Sawing: Key Terms (metal-cutting band saw blades)
A study set for apprentices and operators of metal-cutting band saw machines. Terms include blade designation (width × thickness × ring length), tooth pitch and TPI starting values, tooth set patterns
74
Engineering
Professional
10/04/2026
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Term
TPI (teeth per inch)
 Definition
The number of teeth per inch (25.4 mm) of blade length. A higher TPI means a finer tooth pitch.
Term
Tooth pitch
 Definition
The distance between the tips of two adjacent teeth of a saw blade.
Term
Constant pitch
 Definition
All teeth are identical and equally spaced along the blade.
Term
Variable pitch (e.g. 10/14)
 Definition
Teeth per inch alternate along the blade: 10 on one inch, 14 on the next. Gives a wider working range and less vibration and noise.
Term
Three-teeth rule
 Definition
At least three teeth should be in contact with the material at the same time.
Term
Basis for choosing TPI
 Definition
The minimum working wall thickness in the cut and the section type (profile/tube or solid), not the steel grade or outside diameter.
Term
Pitch too coarse on a thin wall
 Definition
Too few teeth in the cut: impact loading and chipped teeth.
Term
Pitch too fine on a solid section
 Definition
Gullets clog with chips, the blade overheats and the cut slows down.
Term
Starting TPI: steel wall < 3 mm
 Definition
10/14 – 14/18
Term
Starting TPI: solid steel bar > 25 mm
 Definition
2/3 – 4/6
Term
Bi-metal band saw blade
 Definition
A blade with a flexible spring-steel backing and a welded high-speed-steel edge strip in which the teeth are cut.
Term
M42 edge
 Definition
Cobalt high-speed-steel edge (close Russian grade 10R2M10K8); used for structural steels, tubes and profiles.
Term
M51 edge
 Definition
Harder but more brittle edge than M42 (close grade 12R10M4K10); for stainless and alloy steels, solid non-vibrating workpieces.
Term
M71 edge
 Definition
Powder high-speed-steel edge for titanium, nickel-based and heat-resistant alloys.
Term
TCT blade
 Definition
Tungsten-carbide-tipped blade for very hard and abrasive materials; requires a rigid machine.
Term
Blade designation 27×0.9×2455
 Definition
Width × thickness × ring length in millimetres.
Term
Blade ring length
 Definition
Determined by the machine (wheel spacing and size); width and thickness follow the machine manual.
Term
Tooth set
 Definition
Bending of teeth to the sides so that the kerf is wider than the blade body; reduces friction and pinching.
Term
Standard (alternate) set
 Definition
Each tooth bent alternately right and left; under GOST R 53924-2010 not used for blades cutting ferrous metals.
Term
Raker-type set
 Definition
One tooth set right, one left, one unset (straight).
Term
Wavy set
 Definition
Groups of teeth set with a regular change of direction right and left.
Term
Group set
 Definition
Several teeth set alternately right and left, followed by at least one unset tooth.
Term
Set tolerance (GOST R 53924-2010)
 Definition
Set must be equal on both sides of the blade; limit deviation ±0.05 mm.
Term
Blade speed V
 Definition
Linear speed of the band, in m/min, set by an inverter or drive steps.
Term
Typical V for structural steel
 Definition
About 60–85 m/min with bi-metal blades (stainless steel: about 25–35 m/min).
Term
Section productivity Q
 Definition
Cross-section area cut per minute, cm²/min; cut time t ≈ S / Q, where S is the section area.
Term
Blade tension
 Definition
Set according to the machine manual; reference for industrial machines 250–280 N/mm²; re-check after 10–15 min of work.
Term
Blade run-in
 Definition
A new blade works at reduced feed (30–50 % lower) for the first 20–40 minutes.
Term
Blue chip dust
 Definition
Sign that the blade speed is too high or there is not enough coolant.
Term
Curled chip without burning
 Definition
Usually a sign of normal cutting conditions.
Term
Typical emulsion start concentration
 Definition
About 5 % (1 L concentrate to 20 L water), then adjusted to the material.
Term
Emulsion for stainless, heat-resistant steels, titanium
 Definition
About 6–12 % concentration.
Term
Refractometer
 Definition
Instrument for measuring emulsion concentration; the coolant's refractometer factor must be taken into account.
Term
Cut drift
 Definition
The cut line deviates from the intended path; causes include tension, guides, dull teeth, wrong TPI, feed overload and clamping.
Term
Out-of-square cut
 Definition
Constant angle error caused by vise, stop or workpiece seating geometry rather than by blade guidance.
Term
Blade breakage at the weld
 Definition
Typical causes: impact on entry, over-tension, excessive feed on a new blade.
Term
Blade coming off the wheels
 Definition
Typical causes: low tension, oil on the wheels, sudden braking, wrong tooth direction.
Term
TPI (teeth per inch)
 Definition
The number of teeth per inch (25.4 mm) of blade length. A higher TPI means a finer tooth pitch.
Term
Tooth pitch
 Definition
The distance between the tips of two adjacent teeth of a saw blade.
Term
Constant pitch
 Definition
All teeth are identical and equally spaced along the blade.
Term
Variable pitch (e.g. 10/14)
 Definition
Teeth per inch alternate along the blade: 10 on one inch, 14 on the next. Gives a wider working range and less vibration and noise.
Term
Three-teeth rule
 Definition
At least three teeth should be in contact with the material at the same time.
Term
Basis for choosing TPI
 Definition
The minimum working wall thickness in the cut and the section type (profile/tube or solid), not the steel grade or outside diameter.
Term
Pitch too coarse on a thin wall
 Definition
Too few teeth in the cut: impact loading and chipped teeth.
Term
Pitch too fine on a solid section
 Definition
Gullets clog with chips, the blade overheats and the cut slows down.
Term
Starting TPI: steel wall < 3 mm
 Definition
10/14 – 14/18
Term
Starting TPI: solid steel bar > 25 mm
 Definition
2/3 – 4/6
Term
Bi-metal band saw blade
 Definition
A blade with a flexible spring-steel backing and a welded high-speed-steel edge strip in which the teeth are cut.
Term
M42 edge
 Definition
Cobalt high-speed-steel edge (close Russian grade 10R2M10K8); used for structural steels, tubes and profiles.
Term
M51 edge
 Definition
Harder but more brittle edge than M42 (close grade 12R10M4K10); for stainless and alloy steels, solid non-vibrating workpieces.
Term
M71 edge
 Definition
Powder high-speed-steel edge for titanium, nickel-based and heat-resistant alloys.
Term
TCT blade
 Definition
Tungsten-carbide-tipped blade for very hard and abrasive materials; requires a rigid machine.
Term
Blade designation 27×0.9×2455
 Definition
Width × thickness × ring length in millimetres.
Term
Blade ring length
 Definition
Determined by the machine (wheel spacing and size); width and thickness follow the machine manual.
Term
Tooth set
 Definition
Bending of teeth to the sides so that the kerf is wider than the blade body; reduces friction and pinching.
Term
Standard (alternate) set
 Definition
Each tooth bent alternately right and left; under GOST R 53924-2010 not used for blades cutting ferrous metals.
Term
Raker-type set
 Definition
One tooth set right, one left, one unset (straight).
Term
Wavy set
 Definition
Groups of teeth set with a regular change of direction right and left.
Term
Group set
 Definition
Several teeth set alternately right and left, followed by at least one unset tooth.
Term
Set tolerance (GOST R 53924-2010)
 Definition
Set must be equal on both sides of the blade; limit deviation ±0.05 mm.
Term
Blade speed V
 Definition
Linear speed of the band, in m/min, set by an inverter or drive steps.
Term
Typical V for structural steel
 Definition
About 60–85 m/min with bi-metal blades (stainless steel: about 25–35 m/min).
Term
Section productivity Q
 Definition
Cross-section area cut per minute, cm²/min; cut time t ≈ S / Q, where S is the section area.
Term
Blade tension
 Definition
Set according to the machine manual; reference for industrial machines 250–280 N/mm²; re-check after 10–15 min of work.
Term
Blade run-in
 Definition
A new blade works at reduced feed (30–50 % lower) for the first 20–40 minutes.
Term
Blue chip dust
 Definition
Sign that the blade speed is too high or there is not enough coolant.
Term
Curled chip without burning
 Definition
Usually a sign of normal cutting conditions.
Term
Typical emulsion start concentration
 Definition
About 5 % (1 L concentrate to 20 L water), then adjusted to the material.
Term
Emulsion for stainless, heat-resistant steels, titanium
 Definition
About 6–12 % concentration.
Term
Refractometer
 Definition
Instrument for measuring emulsion concentration; the coolant's refractometer factor must be taken into account.
Term
Cut drift
 Definition
The cut line deviates from the intended path; causes include tension, guides, dull teeth, wrong TPI, feed overload and clamping.
Term
Out-of-square cut
 Definition
Constant angle error caused by vise, stop or workpiece seating geometry rather than by blade guidance.
Term
Blade breakage at the weld
 Definition
Typical causes: impact on entry, over-tension, excessive feed on a new blade.
Term
Blade coming off the wheels
 Definition
Typical causes: low tension, oil on the wheels, sudden braking, wrong tooth direction.
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