Need Help with a good cutting method.

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We moved, for lack of a better word, tank stand production in house, we run 10 at a time. Each stand requires at least 25 cuts out of 1/8 2" angle, 2" flat bar and 3" flat bar. This was a job for the evolution rage saw, we bought a rage 3db, the machine does what its supposed to, for about 20 minutes then the blade goes to crap, and I am not abusing this, I am going very slow..I have a portaband, 12" dewalt compound mitre (abrasive blade), the rage, and the plasma, None of these seem to do the job as I want them to, If the rage did its job for atleast 2 hours or more, it would be the best tool.The portaband wont do miters great, nor cut the flat bar in a good amount of time, the compound miter basically mill work dewalt with the abrasive blade pops the 20 amp breaker, and the blades wear out so you cannot cut all the way, and end up spacing off of the fence. The rage, good for about 20 min, We are talking about 250-300 cuts on 1/8th 1-2 times a month.Any suggestions, rather than having 5 blades that get sharpened every time we do a production run?Cold cut saws are expensive and loud from what I hear, which I could care less about loud, Horizontal Band saws you have to "bolt down" every time you do a miter cut.Help!14' PowerMig 210 MP13'Burntables 5x10 CNC Table14' SAE300 HE on a 12' Ram 4500 60 CA 4x4. Custom bed/bottles/reels.87' SA250d, 78 SA200,11' Ranger 250 GXT AC/DCThermal Dynamics Cutmaster 8112' Lincoln Precision Tig 22508' LN25
Reply:That many cuts on angle you need a Piranha ironworker with a coper/notcher and angle shear.  You are going to have a significant up front investment but it will pay dividends with increased production efficiencies.   With those two features (coper/notcher and angle shear) you can work magic on a piece of angle.  I get the luxury of the P-90 but the P-50 seems like it would fit your needs nicely.  Look for a used model or have a broker find you one used. http://www.megafab.com/Piranha_Overview.html Sent from my DROID3 using Tapatalk 2Last edited by jbyrd; 07-10-2012 at 02:01 AM.Jay DavisAWS-CWIC-60 Specialty Welding ContractorLoving husband, and father of two boys (
Reply:I'd say the cold cut saw is good for this, there really not that noisy, not as quiet as a band saw but not that bad really... I think you should be able to get your 250 cuts or so out of one blade no problem, maybe a resharpen for each run.miller 330a bp TIGmiller dynasty 200DX TIGmillermatic 185 MIGthermal dynamics cutmaster 101 plasma cuttersnap-on YA5550 plasma cutterhypertherm powermax 30 plasma cutterbaileigh CS225 cold sawetc....
Reply:I would go with an ironworker first, but if not then a cold cut, they are quieter than abrasive.Dynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:I think a lot of times people  go TOO slow. The common advice is to slow down on the feed rate. This can be as damaging on a carbide blade as going too fast.
Reply:If you have the money, an Ellis saw would be the way I'd go. Miters aren't hard at all to do with one, since it's basically a horizontal bandsaw on a miter saw base.http://www.ellissaw.com/Band-Saws/3/1600-mitre-band-sawYou should be able to get more cut time from a carbide blade. My guess is either you are using the wrong blade, or your technique is wrong and you are going too slow as suggested above..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:A picture would be nice, as well as a description of the cuts, and what material it is on (big difference between SS and Aluminum). I have used my Dewalt multi cutter to get up to 2800 cut through 1/2 hot rolled round bar. Also, on the carbide cutters, are you aware that you cannot do bundles, one piece at a time, or it trashes the blade. Make sure you are presenting the smallest cross section of material to the blade as well. There is no difference to the blade at all between a 1/8 x 3 flat bar and a 3 x 3 solid bar if you lay the flat bar flat on the saw.   Post a pic of the pieces cut, or the stand so we can get a better idea.
Reply:I can back you up on the evolution blades going to crap. I've used 72t 14" metal blades daily for 6 years and recently bought a Evo blade and it lasted a few cuts. Got a replacement blade and it did the same thing. I would never buy a blade or a saw from that company. Depending on your tolerances, an ironworker would crank out the work. Creating some kind of backstop so you don't need to measure each cut would be ideal. Insert material -> jog against backstop -> cut. You can get cold saws brand new pretty affordabley. Check eBay for an idea of pricing for machines that cut the 2" material vs the 4" material. Several USA made saws too. Again, a conveyor based backstop will give you super accurate cuts without having to measure with a tape. I can't get the direct link to work on my cell phone but here is info on their advanced measuring system. I think this can be installed on any saw or ironworker. They are not super expensive either. http://www.scotchman.com/
Reply:Compound miter saw with abrasive wheel?  Have not seen one of those.  Sounds like its a wood cutting machine that you're using for steel.  20amps?  Upgrade your electrical.  14" chop saw for metal should handle this job all day long.  Good luck, and lets see pics!-AaronJet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:Want to sell the evolution saw in question?  I'd like to have the double bevel version.
Reply:Originally Posted by Showdog75Want to sell the evolution saw in question?  I'd like to have the double bevel version.
Reply:Purchase pre-cut  parts. Seems like it would free a lot of time.  Otherwise an Iron worker would be my suggestion. Your are not looking at much tonnage nor high use for that specific job.  I have an old mechanical ironworker that would knock that quickly. However, mechanical ironworker are scary, especially with multiple users.
Reply:The first thing I'd try is a better blade on the Evolution saw.Jack OlsenMy garage website
Reply:http://tubefabricatingtools.vogeltoo...&bc=100%7C1007Might find a die set to fit into a press.
Reply:I tried the blade that came with the evolution saw, and then ordered their mild steel specific blade.I will get a picture tomorrow.@ Fronty I was using very light pressure, are you supposed to just give it firm pressure like an abrasive blade? I was far above bogging the motor down, a review on this board said that you need to use very light pressure to keep the blades from dulling@ Walker, I was doing 2 pieces of angle at a time, cutting from the peak to the ends. Might have been my problem but the saw is was rated higher then a 1/4" cut. 20amps on 120 should be plenty. More power would likely ruin the saw, its a standard commercial circuit.@Tapwelder, we are trying to reduce costs, at $1.50 a cut, its worth it to cut it myself, plus I like having the tools at my disposal@jack, any suggestions on a better blade? 1" arbor, 10" blade@rabidchimp, its a compound miter saw, that is made for wood, and i put an abrasive blade in it, 12"14' PowerMig 210 MP13'Burntables 5x10 CNC Table14' SAE300 HE on a 12' Ram 4500 60 CA 4x4. Custom bed/bottles/reels.87' SA250d, 78 SA200,11' Ranger 250 GXT AC/DCThermal Dynamics Cutmaster 8112' Lincoln Precision Tig 22508' LN25
Reply:@showdog its going back to amazon as a return I just bought it, as is the "mild steel" blade14' PowerMig 210 MP13'Burntables 5x10 CNC Table14' SAE300 HE on a 12' Ram 4500 60 CA 4x4. Custom bed/bottles/reels.87' SA250d, 78 SA200,11' Ranger 250 GXT AC/DCThermal Dynamics Cutmaster 8112' Lincoln Precision Tig 22508' LN25
Reply:Ive owned the Makita cold cut saw now for about 10 years.Done a few production runs with good results.Ive only ever used genuine Makita blades.  You will get quite a few cuts out of a blade on mild steel.
Reply:Can you post something similar to what you have LarryO, and a price to a machine that is comparable. Ill google it now,14' PowerMig 210 MP13'Burntables 5x10 CNC Table14' SAE300 HE on a 12' Ram 4500 60 CA 4x4. Custom bed/bottles/reels.87' SA250d, 78 SA200,11' Ranger 250 GXT AC/DCThermal Dynamics Cutmaster 8112' Lincoln Precision Tig 22508' LN25
Reply:This is the one ive got.The price i paid is in AU$.  sorry.http://www.makita.com.au/product-pag...al-cutting-saw
Reply:This one........ Attached Images
Reply:Thanks Larry, any opinion on a 12 inch versus 14 inch?14' PowerMig 210 MP13'Burntables 5x10 CNC Table14' SAE300 HE on a 12' Ram 4500 60 CA 4x4. Custom bed/bottles/reels.87' SA250d, 78 SA200,11' Ranger 250 GXT AC/DCThermal Dynamics Cutmaster 8112' Lincoln Precision Tig 22508' LN25
Reply:The extra cut depth would be handy.  Blades would be more expensive.  They are already expensive for the 12".Ive got the 12".  Im not sur the 14" is available in Australia.  Haven't seen one.
Reply:the first blade that came with my Steel Max saw lasted a short time because i tried to baby it when cutting. the old boy that i sent my blades to to be sharped told me that going to slow will waste a carbide blade fast. he told me that while cutting, put enough pressure on the down feed to where the motor sounds like it is just starting to work and follow it through. the new Evolution blade i have on my saw has been cutting everything from 1/8" up angle ^ (point up) to 1/2" flat bar on edge for 4+- months now on a daily basis. i can't complain about the life i am getting out of the Evo blade but i will pay the extra for the Steel Max blades from now till their quality takes a dump. my question to the OP is, are you buying the heavy duty "Steel" series blades or the universal blades for use on the Rage?225NT bobcatAEAD200LEScott 125mm175, mm252 w 30A, PT225mm211, TA 181iHyper Therm 380, cut master 529100X & XX, Digital Elite6 Victor setssmith little torch, meco midget kalamazoo band sawsteel max saw evoulution circular saw
Reply:On a production run, i once became complacent and didn't tighten the clamp properly.Trashed a $300+ blade real quick.  Buckled. Now i just take a little extra time to ensure it doesn't happen again.