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BAND SAW BLADE

REFERENCE GUIDE
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Webber Gage Blocks Bulletin 1037

 Cutting Table for
Bi-Metal Band Saw Blades
Work piece dimension (in) 2-5" (20-125mm) 2-5" 50-125mm
Cutting Table

Speed/Cutting Index Blade Speed Cut Rate Blade Speed Cut Rate
Work Material Type ABNT/AISI/SAE Hardness ft/min. in2/min. m/min. cm2/min.
1005-1012 150HB 259-298 30-40 79-91 77-103
1015-1026 150HB 249-288 27-38 76-88 71-97
Carbon Steels
1030-1055, A36 175HB 180-219 20-22 55-67 52-58
1060-1095 200HB 160-200 15-20 49-61 39-52
1110-1117-1118 150HB 259-321 30-40 79-98 77-103
Easy-to-machine carbon Steels 1137-1151 175HB 219-259 20-30 67-79 52-77
1211-1215 150HB 259-321 38-47 79-98 97-120
1330-1345 200HB 180-219 15-20 55-67 39-52
1513-1527 150HB 259-298 30-40 79-91 77-103
Manganese steels
1536-1552 175HB 200-259 20-25 61-79 52-65
1561-1572 200HB 160-200 15-20 49-61 39-52
4012-4024 175HB 200-239 17-22 61-73 45-58
Molybdenum steels 4030-4042 175HB 190-229 17-20 58-70 45-52
4047-4068 175HB 180-219 15-20 55-67 39-52
4130-4140 200HB 180-219 15-20 55-67 39-52
Chrome Moly Steels
4142-4161 200HB 170-209 12-17 52-64 32-45
4320 175HB 200-239 17-22 61-73 45-58
4340 200HB 180-219 15-20 55-67 39-52
8115, 8615-8622, 8145, 8625-8637 175HB 200-239 17-22 61-73 45-58
Nickel Chrome Moly Steels 8640-8660, 8740 200HB 180-219 15-20 55-67 39-52
8720, 8822 200HB 200-239 17-22 61-73 45-58
9310 175HB 160-190 7-10 49-58 19-26
9430-9445 200HB 180-219 15-20 55-67 39-52
Nickel Moly Steels 4625-4626, 4815-4820 175HB 200-239 17-22 61-73 45-58
5040-5060 200HB 180-219 15-20 55-67 39-52
5115-5120 175HB 200-239 17-22 61-73 45-58
Chrome Steels
5130-5160 200HB 180-219 15-20 55-67 39-52
50100, 51100, 52100 225HB 131-160 10-12 40-49 26-32
6118 175HB 200-239 17-22 61-73 45-58
Chrome Vanadium Steel
6150 200HB 180-219 15-20 55-67 39-52
Silicon steels 9255-9262 200HB 180-219 15-20 55-67 39-52
A2-A6, A8-A10 200HB 180-219 7-10 55-67 19-26
Tool steels-Cold work D2-D7, A7 250HB 65-98 5-7 20-30 13-19
O1, O2, O6, O7 200HB 180-219 10-15 55-67 26-39
H10-H19, H21-H42, P20 200HB 131-160 7-10 40-49 19-26
Tool steels-Hot work L2, L6 200HB 170-209 7-10 52-64 19-26
S1-S7 200HB 131-160 7-10 40-49 19-26
Carbon tool steels W1-W5 200HB 180-219 10-15 55-67 26-39
Ferritic stainless steels 405, 409, 430, 434, 436, 442, 446 175HB 78-98 7-10 24-30 19-26
M1, M2, M7, M10 225HB 111-131 7-10 34-40 19-26
M3, M4, M30-M47 225HB 65-98 5-7 20-30 13-19
High speed steels T1, T2, T6 250HB 111-131 7-10 34-40 19-26
T15 250HB 59-88 5-7 18-27 13-19
T4, T5 250HB 88-121 5-7 27-37 13-19
201, 202, 301-305, 308, 321, 347 150HB 98-121 7-10 30-37 19-26
Austenitic stainless steels
A286, 309, 310, 314, 316, 317, 330 175HB 68-78 3-5 21-24 10-13

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 Cutting Table
Work piece dimension (in) 2-5" (20-125mm) 2-5" 50-125mm
Speed/Cutting Index Blade Speed Cut Rate Blade Speed Cut Rate
Work Material Type ABNT/AISI/SAE Hardness ft/min. in2/min. m/min. cm2/min.
330 150HB 98-141 10-12 30-43 26-32
Easy-to-machine Stainless Steels
416, 420F, 430F 150HB 141-180 12-15 43-55 32-39
403, 410, 420, 422, 501, 502 175HB 98-131 7-10 30-40 19-26
Martensitic stainless steels
440A-C, 414, 431 225HB 88-98 7-10 27-30 19-26
Hardened Stainless Steel 15-5PH, 17-4PH, 17-7PH 200HB 68-88 5-7 21-27 13-19
Class 20 125HB 160-200 27-38 49-61 71-97
Class 40 200HB 121-160 20-30 37-49 52-77
Cast iron
Malleable 60-40-18 150HB 200-249 20-25 61-76 52-65
Malleable 80-55-06 225HB 121-160 12-17 37-49 32-45
Hastelloy, Rene 41 250HB 49-68 2-2 15-21 6-6
Inconel 600, 601 250HB 59-78 5-7 18-24 13-19
Nickel alloys Inconel 625, 718, Waspaloy 250HB 59-78 2-5 18-24 6-13
Monel 400, 401 250HB 68-88 5-7 21-27 13-19
Monel K500 250HB 59-78 2-5 18-24 6-13
Alpha, Alpha-Beta, Beta 325HB 45-59 2-2 14-18 6-6
Titanium alloys
Titanium 99% 150HB 68-88 2-5 21-27 6-13
Columbium - 59-78 2-2 18-24 6-6
Refractory metals Molybdenum - 78-98 2-2 24-30 6-6
Tantalum - 49-59 2-2 15-18 6-6
Tempered Aluminum Bronze 30HRC 78-98 3-5 24-30 10-14
Tempered Beryllium Copper 38HRC 39-55 1-2 12-17 3-6
Aluminum Bronze 70HRB 164-190 15-20 50-58 39-52
Phosphor Bronze 70HRB 150-190 20-25 46-58 52-65
Copper alloys
Copper 99% 50HRB 141-180 17-22 43-55 45-58
Copper Belirio 70HRB 170-190 10-15 52-58 26-39
Yellow/Red Brass 70HRB 200-259 20-25 61-79 52-65
Easy machining brass 70HRB 219-249 25-30 67-76 65-77
1200 30HB
2024 120HB
Aluminum Alloys 5052 50HB 393-442 30-43 120-135 77-110
6061 110HB
7075 160HB

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 Troubleshooting
Blade Effect Probable Cause Solution
Troubleshooting

Blade Breakage Incorrect blade. Check tooth selection.

Incorrect blade tension. Adjust the blade tension, refer to operator's manual.
Excessive feed. Reduce feed pressure.
Incorrect cutting fluid. Check coolant recommendations.
Pressure blocks too tight. Adjust the guides.
Blade rubbing on wheel flange. Adjust wheel alignment.
Guide arms too far apart. Adjust guide arms closer to material.
(straight break indicates fatigue) Side guides too tight. Adjust guides.
Premature Wear of the Teeth Blade on machine backwards. Install blade correctly.
Improper blade break-in procedure. Refer to recommended procedures.
Hard Material or heavy surface scale. Check material hardness and surface conditions.
Hard Material. Increase feed pressure.
Improper cutting fluid or mix ratio. Follow coolant mixing procedures.
Speed or feed too high. Check cutting recommendations.
Cut Unspecified Guide arms too far apart. Adjust guide arms closer to material.
Blade worn out. Replace blade.
Over or under feeding. Check cutting recommendations.
Improper tooth pitch. Use proper tooth selection.
Cutting fluid not applied properly. Adjust coolant nozzles.
Guides worn or loose. Tighten or replace guides.
Cutting Deviation Over feeding. Check cutting recommendations.
Low band tension. Refer to operator's manual.
Tooth set damaged. Check material hardness, replace blade.
Guide arms loose or space too wide. Adjust guides and guide arms.
Chips Residues in the Teeth Worn or missing chip brush. Replace or adjust chip brush.
Improper or lack of cutting fluid. Check coolant flow and fluid type.
Wrong coolant rate. Check coolant type and ratio.
Excessive feed or speed. Reduce speed or feed.
Incorrect blade pitch. Use proper tooth selection.
Tooth - Breaking Away Saw guides not properly adjusted. Align or adjust saw guides.
Incorrect feed or speed. Refer to cutting recommendations.
Incorrect blade. Use proper blade type and pitch.
Material moved in vise. Inspect and adjust vise.
Wear Only on One Side of the Teeth Material with impurities. Replace material.
Wheel with worn flange and band rising out of
Align or replace wheel.
the track.
Guide rubbing on set. Adjust and align guide.
Chipping teeth and embedding within the
Replace blade and apply correct break-in.
material.
Breaks of the Teeth Improper blade break-in procedure. Follow proper break-in procedure.
Speed too slow. Refer to cutting recommendations.
Feed pressure too high. Reduce feed pressure.
Tooth jammed in cut. Low speed and high cutting pressure.
Poor cutting fluid application or ratio. Adjust coolant flow and ratio.
Hard material or heavy scale. Check material or surface hardness.
Wrong blade pitch. Use proper tooth selection.
Work spinning or loose nested bundles. Tighten vise or use nesting clamps.
Cut beginning over the corner of the material. Start the cut slowly.

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 Blade Effect Probable Cause Solution
Wear on the Back of the Blade Excessive back-up guide preload. Adjust pressure block.
Low blade tension. Refer to operator's manual.
Blade worn out. Replace blade.

Troubleshooting
Excessive feed rate or pressure. Reduce feed rate or pressure.
Damaged or worn pressure block. Replace pressure block.
Guide arms spaced too far apart or too tight. Adjust guides.
Blade rubbing band wheel flanges. Adjust wheel alignment.
Incorrect guide alignment. Align guides.
Wavy Cut Dull or damaged blade. Install new blade.
Incorrect feed or speed. Refet to cutting recommendations.
Blade not supported properly. Adjust or tighten guide arms.
Low blade tension. Refer to operator's manual.
Incorrect tooth pitch. Use proper tooth selection.
(cardboard surface, vibration and/or risks) Guide arms too far apart. Adjust guide arms closer to material.
Frayed Lines of Loss Hangs Saw side guides too tight. Adjust guides properly.
Blade riding too high in guide. Adjust rollers or pressure blocks.
Blade teeth riding on band wheel surface. Adjusting tracking or replace wheel.
Wrong blade width for machine. Refer to operator's manual.
Chips being carried back into cut. Replace or adjust chip brush.
Worn or damaged guides. Replace guides.
Insufficient cooling flow. Adjust coolant flow.
Blade Twisted Blade binding in cut. Adjust feed.
Guides misaligned. Adjust and align guides.
Side guides are too tight. Adjust guides.
Work loose in vise. Adjust vise.
Feed too heavy. Reduce feed pressure.
High blade tension. Refer to operator's manual.
Worn wheels. Machine or replace wheels.
Guides arms too far apart. Adjust guide arms closer to material.

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 Cut Rate Chart
Bar Cutting Rate in Square Inches per Minute
Diameter Area (in2) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Minutes per Cut
1.00 0.79 .79 .39 .26 .20 .16 .13 .11 .10 .09 .08 .07 .07 .06 .06 .05 .05 .05 .04
Cutting Rate

1.25 1.23 1.2 .61 .41 .31 .25 .20 .18 .15 .14 .12 .11 .10 .09 .09 .08 .08 .07 .07
1.50 1.77 1.8 .88 .59 .44 .35 .29 .25 .22 .20 .18 .16 .15 .14 .13 .12 .11 .10 .10
1.75 2.41 2.4 1.2 .80 .60 .48 .40 .34 .30 .27 .24 .22 .20 .19 .17 .16 .15 .14 .13
2.00 3.14 3.1 1.6 1.0 .79 .63 .52 .45 .39 .35 .31 .29 .26 .24 .22 .21 .20 .18 .17
2.25 3.98 4.0 2.0 1.3 1.0 .80 .66 .57 .50 .44 .40 .36 .33 .31 .28 .27 .25 .23 .22
2.50 4.91 4.9 2.5 1.6 1.2 1.0 .82 .70 .61 .55 .49 .45 .41 .38 .35 .33 .31 .29 .27
2.75 5.94 5.9 3.0 2.0 1.5 1.2 1.0 .85 .74 .66 .59 .54 .49 .46 .42 .40 .37 .35 .33
3.00 7.07 7.1 3.5 2.4 1.8 1.4 1.2 1.0 .88 .79 .71 .64 .59 .54 .50 .47 .44 .42 .39
3.25 8.30 8.3 4.1 2.8 2.1 1.7 1.4 1.2 1.0 .92 .83 .75 .69 .64 .59 .55 .52 .49 .46
3.50 9.62 9.6 4.8 3.2 2.4 1.9 1.6 1.4 1.2 1.1 1.0 .87 .80 .74 .69 .64 .60 .57 .53
3.75 11.04 11.0 5.5 3.7 2.8 2.2 1.8 1.6 1.4 1.2 1.1 1.0 .92 .85 .79 .74 .69 .65 .61
4.00 12.57 12.6 6.3 4.2 3.1 2.5 2.1 1.8 1.6 1.4 1.3 1.1 1.0 1.0 .90 .84 .79 .74 .70
4.25 14.19 14.2 7.1 4.7 3.5 2.8 2.4 2.0 1.8 1.6 1.4 1.3 1.2 1.1 1.0 .95 .89 .83 .79
4.50 15.90 15.9 8.0 5.3 4.0 3.2 2.7 2.3 2.0 1.8 1.6 1.4 1.3 1.2 1.1 1.1 1.0 .94 .88
4.75 17.72 17.7 .89 5.9 4.4 3.5 3.0 2.5 2.2 2.0 1.8 1.6 1.5 1.4 1.3 1.2 1.1 1.0 1.0
5.00 19.64 19.6 9.8 6.5 4.9 3.9 3.3 2.8 2.5 2.2 2.0 1.8 1.6 1.5 1.4 1.3 1.2 1.2 1.1
5.25 21.65 21.6 10.8 7.2 5.4 4.3 3.6 3.1 2.7 2.4 2.2 2.0 1.8 1.7 1.5 1.4 1.4 1.3 1.2
5.50 23.76 23.8 11.9 7.9 5.9 4.8 4.0 3.4 3.0 2.6 2.4 2.2 2.0 1.8 1.7 1.6 1.5 1.4 1.3
5.75 25.97 26.0 13.0 8.7 6.5 5.2 4.3 3.7 3.2 2.9 2.6 2.4 2.2 2.0 1.9 1.7 1.6 1.5 1.4
6.00 28.27 28.3 14.1 9.4 7.1 5.7 4.7 4.0 3.5 3.1 2.8 2.6 2.4 2.2 2.0 1.9 1.8 1.7 1.6
6.25 30.68 30.7 15.3 10.2 7.7 6.1 5.1 4.4 3.8 3.4 3.1 2.8 2.6 2.4 2.2 2.0 1.9 1.8 1.7
6.50 33.18 33.2 16.6 11.1 8.3 6.6 5.5 4.7 4.1 3.7 3.3 3.0 2.8 2.6 2.4 2.2 2.1 2.0 1.8
6.75 35.78 35.8 17.9 11.9 8.9 7.2 6.0 5.1 4.5 4.0 3.6 3.3 3.0 2.8 2.6 2.4 2.2 2.1 2.0
7.00 34.48 38.5 19.2 12.8 9.6 7.7 6.4 5.5 4.8 4.3 3.8 3.5 3.2 3.0 2.7 2.6 2.4 2.3 2.1
7.25 41.28 41.3 20.6 13.8 10.3 8.3 6.9 5.9 5.2 4.6 4.1 3.8 3.4 3.2 2.9 2.8 2.6 2.4 2.3
7.50 44.18 44.2 22.1 14.7 11.0 8.8 7.4 6.3 5.5 4.9 4.4 4.0 3.7 3.4 3.2 2.9 2.8 2.6 2.5
7.75 47.17 47.2 23.6 15.7 11.8 9.4 7.9 6.7 5.9 5.2 4.7 4.3 3.9 3.6 3.4 3.1 2.9 2.8 2.6
8.00 50.27 50.3 25.1 16.8 12.6 10.1 8.4 7.2 6.3 5.6 5.0 4.6 4.2 3.9 3.6 3.4 3.1 3.0 2.8
8.25 53.46 53.5 26.7 17.8 13.4 10.7 8.9 7.6 6.7 5.9 5.3 4.9 4.5 4.1 3.8 3.6 3.3 3.1 3.0
8.50 56.75 56.7 28.4 18.9 14.2 11.3 9.5 8.1 7.1 6.3 5.7 5.2 4.7 4.4 4.1 3.8 3.5 3.3 3.2
8.75 60.13 60.1 30.1 20.0 15.0 12.0 10.0 8.6 7.5 6.7 6.0 5.5 5.0 4.6 4.3 4.0 3.8 3.5 3.3
9.00 63.62 63.6 31.8 21.2 15.9 12.7 10.6 9.1 8.0 7.1 6.4 5.8 5.3 4.9 4.5 4.2 4.0 3.7 3.5
9.25 67.20 67.2 33.6 22.4 16.8 13.4 11.2 9.6 8.4 7.5 6.7 6.1 5.6 5.2 4.8 4.5 4.2 4.0 3.7
9.50 70.88 70.9 35.4 23.6 17.7 14.2 11.8 10.1 8.9 7.9 7.1 .64 5.9 5.5 5.1 4.7 4.4 4.2 3.9
9.75 74.66 74.7 37.3 24.9 18.7 14.9 12.4 10.7 9.3 8.3 7.5 6.8 6.2 5.7 5.3 5.0 4.7 4.4 4.1
10.0 78.54 78.5 39.3 26.2 19.6 15.7 13.1 11.2 9.8 8.7 7.9 7.1 6.5 6.0 5.6 5.2 7.7 4.6 4.4

Recommended Tension Reading the Chips

Width English System Metric System Chip Chip Chip Blade Blade
Saw Blades in mm lb/in² (PSI) (kg/cm²) Formation Condition Color Speed Feed Other
Primalloy™; Intenss™ PRO-VTH; Intenss™ Refer to machine
3/4, 1 end 19, 27
PRO; Versatix™ MP; Intenss™; Advanz™ MC7, 20,000-35,000 1,400-2,500 Thin and recommendations
1-1/4 end 34 Silver Correct Decrease
Advanz™ MC5, TS, CS, FS and CG Tightly Curled for correct tooth
Primalloy™; Intenss™ PRO-VTH; Intenss™ PRO; pitch
1-1/2 or 41 or
Versatix™ MP; Intenss™; Advanz™ MC7, MC5, 30,000-40,000 2,100-2,800
greater greater
Advanz™ TS, CS and FS
Intenss™; Intenss™ PRO-DIE; Univerz™; Duratec™ Powdered Silver Decrease Increase
Up to 1/2 Up to 16 20,000-25,000 1,400-1,800
SFB; Band Knives High-carbon Steel
Duratec™ SFB; Duratec™ FC; Band
Above 3/4 Above 19 20,000-30,000 1,400-2,100
Knives High-carbon Steel
Power Hacksaw Blades 1-1/2 or less 41 or less 20,000-30,000 1,400-2,100 Thick and Blue or Check cutting
1-3/4 or 45 or Decrease Decrease
Power Hacksaw Blades 25,000-35,000 1,800-2,500 Short Brown fluid
greater greater
The above tension ranges are supplied as a guide for normal average cutting conditions. Insufficient blade tension can
effect the cutting efficiency of the blade. Excessive tension may cause breakage of band saw blades.
As a general rule of thumb, the higher end of the tension range should be used when the guide arms are further apart Thin and
Silver Correct Correct
and the lower end of the range should be used when the guide arms are closer together. Curly

6
Cut-Off Calculation

Cut-Off Calculation
Tube or Strucutural Material Cutting
Area Calculation To calculate the material area, choose the tooth, speed and cutting rate, however correct
Use the measurements below in inches to the cutting feed (cutting time), by multiplying the time calculated by the correction
obtain the area in in2. factor, according to table below.

SQUARE Correction Factor of Cutting Time

area = L2 2.5
2
1.7
1.4
1.2
NOTE: when dry cutting, adjust the feed pressure to about 40%-
ROUND 50% the normal cutting rate (use data on pages 2 and 3).

area = D2 x 0.7854 NOTE: dry cutting reduces the blade life

Example of Cutting Calculation

Material: austenitic stainless steel (SAE 316)
ROUND TUBE Format: round
area = (De2-Di2) x 0.7854 Dimension: 4" (101.6mm)
Speed: 68 to 78ft/min.* (21 to 24 m/min.*)
Cutting Index: 3 to 5in² min* (10 to 13cm² min*)
TC = Cutting Time
A
TC = A = Material Area
IC
IC = Cutting Index
SQUARE TUBE
TC = 12.50in² ÷ 5in²/min. (31.75cm² ÷ 13cm²/min.)
area = Le2-Li2
TC = 2.5 minutes

RECTANGLE
area = E x L

HEXAGON
area = L2 x 2.598
E2 x 0.866

For Duratec™ SFB Carbon Steel Blades: adjust the feed pressure
to 50% the normal cutting and the Cutting Index to 85%.

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 BAND SAW BLADE REFERENCE GUIDE

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starrett.com Bulletin 1037 Band Saw Blade Reference Guide 05/14 The L.S. Starrett Company 2014© Specifications subject to change.