PERFORMING CUTTING Cut flat bar -is an act of removing some kind of materials from the main body

to make a smooth flat bar. Normally flat bar is a kind of steel product bearing rectangle section, with the range of width from 12 to 300 mm and that of thickness from 4 to 60mm.The specification can be described by the unit of thickness*width. Flat bar can be either used as hot-rolled finished product or billet cut from plate. Power saw this is a power tool used for cutting wood materials, an endless saw consisting of a toothed metal band that is driven around two wheels.

Straight sawing- Straight-line sawing is the most common machine sawing operation. It may be performed using the power hacksaw, horizontal, or vertical band saw Vertical sawing- When laying out workpieces for vertical sawing operations, consider the size of the stock in relation to the clearance of the bandsaw machine column. For straight-line sawing the clearance is easy to judge, but for contour sawing of large size stock, the directions of cut must be carefully figured to prevent the stock from hitting the column. If a small section is to be cut from a large sheet of metal, the section should be roughly cut oversize from the sheet and then carefully cut to the prescribed outline. Explain the main parts of power sawing machine DESCRIPTION All power saw machines are basically similar in design. Figure 6-1 shows a typical power saw and identifies its main parts, which are discussed below.

Base The base of the saw usually contains a coolant reservoir and a pump for conveying the coolant to the work. The reservoir contains baffles which cause the chips to settle to the bottom of the tank. A table

which supports the vise and the metal being sawed is located on top of the base and is usually referred to as part of the base. Vise The vise is adjustable so that various sizes and shapes of metal may be held. On some machines the vise may be swiveled so that stock may be sawed at an angle. The size of a power hacksaw is determined by the largest piece of metal that can be held in the vise and sawed. Frame The frame of the saw supports and carries the hacksaw blade. The machine is designed so that the saw blade contacts the work only on the cutting stroke. This action prevents unnecessary wear on the saw blade. The cutting stroke is on the draw or back stroke. Some machines feed by gravity, the saw frame having weights that can be shifted to give greater or less pressure on the blade. Other machines are power fed with the feed being adjustable. On these machines, the feed is usually stopped or reduced automatically when a hard spot is encountered in the material, thus allowing the blade to cut through the hard spot without breaking. Name the most cut-off and contour band saw CONTOUR SAWING Contour sawing is the process of cutting shapes in which the direction of the cut must be changed at intervals. Holes larger in diameter than the width of the saw blade must be drilled at each corner where a change of direction of the bandsaw blade will occur. Figure 6-20 illustrates the methods of changing direction of a cut at a hole. Explain the factors which guide selection of the proper blade Blade Selection Care must be taken to select a bandsaw blade of the proper width for the radius or circle to be cut. If the blade is too wide for the radius, the heel of the blade will press against the outer edge of the kerf (in Figure ). When the heel contacts this edge, any further twisting of the workpiece in an attempt to cut a sharper radius will twist the bandsaw blade and may result in the blade breaking. Cutting Pressure When cutting a radius, apply a slight side pressure at the inner cutting edge of the bandsaw blade. This pressure will give the blade a tendency to provide additional clearance.

Cutting fluid Cutting fluid is a type of coolant and lubricant designed specifically for metalworking and machining processes. There are various kinds of cutting fluids, which include oils, oil-water emulsions, pastes, gels, aerosols (mists), and air or other gases. They may be made from petroleum distillates, animal fats, plant oils, water and air, or other raw ingredients. Depending on context and on which type of cutting fluid is

being considered, it may be referred to as cutting fluid, cutting oil, cutting compound, coolant, or lubricant. Most metalworking and machining processes can benefit from the use of cutting fluid, depending on workpiece material. Common exceptions to this are machining cast iron and brass, which are machined dry. The properties that are sought after in a good cutting fluid are the ability to:

Keep the workpiece at a stable temperature (critical when working to close tolerances). Very warm is OK, but extremely hot or alternating hot-and-cold are avoided. Maximize the life of the cutting tip by lubricating the working edge and reducing tip welding. Ensure safety for the people handling it (toxicity, bacteria, fungi) and for the environment upon disposal. Prevent rust on machine parts and cutters.

Functions of cutting fluids; Cooling Metal cutting operations generate heat due to tool friction and energy lost deforming the material. The surrounding air is a poor coolant for the cutting tool because it conducts heat poorly and has low thermal conductivity. Ambient-air cooling is adequate for light cuts and low duty cycles typical of maintenance, repair and operations (MRO) or hobbyist work. However, production work requires heavy cutting over long time periods and typically produces more heat than air cooling can remove. Rather than pausing production while the tool cools, using liquid coolant removes significantly more heat more rapidly, and can also speed cutting and reduce friction and tool wear. Lubrication Besides cooling, cutting fluids also aid the cutting process by lubricating the interface between the tool's cutting edge and the chip. By preventing friction at this interface, some of the heat generation is prevented. This lubrication also helps prevent the chip from being welded onto the tool, which interferes with subsequent cutting. Delivery methods of cutting fluids Every conceivable method of applying cutting fluid (e.g., flooding, spraying, dripping, misting, brushing) can be used, with the best choice depending on the application and the equipment available. Types of cutting fluids Liquids There are generally three types of liquids: mineral, semi-synthetic, and synthetic. Semi-synthetic and synthetic cutting fluids represent attempts to combine the best properties of oil with the best properties of water by suspending emulsified oil in a water base. These properties include: rust inhibition, tolerance of a wide range of water hardness (maintaining pH stability around 9 to 10), ability to work with many metals, resist thermal breakdown, and environmental safety.[1] Water is a good conductor of heat but has drawbacks as a cutting fluid. It boils easily, promotes rusting of machine parts, and does not lubricate well. Therefore, other ingredients are necessary to create an optimal cutting fluid. Pastes or gels

Cutting fluid may also take the form of a paste or gel when used for some applications, in particular hand operations such as drilling and tapping. In sawing metal with a bandsaw, it is common to periodically run a stick of paste against the blade. This product is similar in form factor to lipstick or beeswax. It comes in a cardboard tube, which gets slowly consumed with each application. Aerosols (mists) Some cutting fluids are used in aerosol (mist) form (air with tiny droplets of liquid scattered throughout). The main problems with mists have been that they are rather bad for the workers, who have to breathe the surrounding mist-tainted air, and that they sometimes don't even work very well. Both of those problems come from the imprecise delivery that often puts the mist everywhere and all the time except at the cutting interface, during the cutthe one place and time where it's wanted. However, a newer form of aerosol delivery, MQL (minimum quantity of lubricant), [2][3] avoids both of those problems. The delivery of the aerosol is directly through the flutes of the tool (it arrives directly through or around the insert itselfan ideal type of cutting fluid delivery that traditionally has been unavailable outside of a few contexts such as gun drilling or expensive, state-of-the-art liquid delivery in production milling). MQL's aerosol is delivered in such a precisely targeted way (with respect to both location and timing) that the net effect seems almost like dry machining from the operators' perspective.[2][3] The chips generally seem like dry-machined chips, requiring no draining, and the air is so clean that machining cells can be stationed closer to inspection and assembly than before.[2][3] MQL doesn't provide much cooling in the sense of heat transfer, but its well-targeted lubricating action prevents some of the heat from being generated in the first place, which helps to explain its success. CO2 Coolant Carbon Dioxide (chemical formula CO2) is also used as a coolant. In this application pressurized liquid CO2 is allowed to expand and following the ideal gas law, this is accompanied by a drop in temperature, enough to cause a change of phase into a solid. These solid crystals are redirected into the cut zone by either external nozzles or through-the-spindle delivery, to provide temperature controlled cooling of the cutting tool and work piece.The ChilAire system is one of the pioneers in the application of CO2 as a coolant. Existing CNC machines can be retrofitted with this safe and environmentally friendly coolant approach. In applications such as turning, milling or drilling tool life and throughput have been improved substantially; especially in high temperature alloys such as titanium, 4140, steels and plastics. Air or other gases (e.g., nitrogen) Ambient air, of course, was the original machining coolant. Compressed air, supplied through pipes and hoses from an air compressor and discharged from a nozzle aimed at the tool, is sometimes a useful coolant. The force of the decompressing air stream blows chips away, and the decompression itself has a slight degree of cooling action. The net result is that the heat of the machining cut is carried away a bit better than by ambient air alone. Sometimes liquids are added to the air stream to form a mist (mist coolant systems, described above). Liquid nitrogen, supplied in pressurized steel bottles, is sometimes used in similar fashion. In this case, boiling is enough to provide a powerful refrigerating effect. For years this has been done (in limited applications) by flooding the work zone. Since 2005, this mode of coolant has been applied in a manner comparable to MQL (with through-the-spindle and through-the-tool-tip delivery). This refrigerates the body and tips of the tool to such a degree that it acts as a "thermal sponge", sucking up the heat from the toolchip interface.[5] This new type of nitrogen cooling is still under patent. Tool life has been increased by a factor of 10 in the milling of tough metals such as titanium and inconel.[5] Name different types of band saws and their uses A band saw is either a tall machine that sits on the floor, or, it's a smaller, shorter machine that sits on top of a bench. It is made up of an outside casing that covers the motor, pulleys, and other inner

workings. There is also a cordless, portable type of band saw that can be taken from job to job by contractors. It runs on an eighteen volt, rechargeable battery pack. It is obviously smaller and lighter than the other two types of band saws The different types of blades are as follows: a regular tooth band is most often used for cutting wood. A skip tooth blade is best used for cutting pieces of soft woods; and a hooked tooth blade is made for cutting through pieces of hard woods. You can also purchase a special diamond blade that is able to saw through pieces of glass. And, there is a hardened blade that can cut through metal. These blades come in varied tooth sizes, tooth shapes, band material, et cetera. You can purchase blade widths that range from an eighth of an inch to three quarters of an inch in width. Thin, flexible blades are used to cut curved or rounded pieces, while wide blades are strictly used for cutting straight lines. By using the proper type of blade, you can cut almost any type of material, including soft wood, hard wood, thin steel, copper, conduit, metals, glass, galvanized pipe, and PVC pipe. Once you have chosen the proper band saw blade, and have installed it, you should make sure it is adjusted so it is positioned on the center of the pulleys. The tension of the blade should also be tight enough to keep the blade from slipping. Read and follow your owner's manual in order to achieve the best results. When you use a band saw, for safety's sake, you should always wear protective eye wear. Also, make sure that you keep your hands away from the blade. Adjust the guard so that is just clears the top of the material you are going to cut. Remember that the lesser number of blade teeth that are exposed, the safer you will be Apply safety requirement during flat sawing Use a miter guide attachment, work-holding jaw device, or a wooden block for pushing metal workpieces into the blade of the bandsaw wherever possible. Keep fingers well clear of the blade at all times. Keep hands away from the saw blade of the hacksawing machine or bandsawing machine when in operation. When removing and installing band saw blades, handle the blades carefully. Large springy blades can be dangerous if the operator does not exercise caution. Ensure the power supply is disconnected prior to removal or installation of saw blades.

Perform flat sawing Flat sawing is the most commonly used diamond cutting method. It is typically used to cut horizontal flat surfaces such as floors, bridge decks, and pavements. Also called slab saws, flat saws feature a diamond blade that is mounted on a walk-behind machine requiring only one operator. Flat saws are typically used to provide expansion joints, remove damaged pavement sections, clean and repair random cracks for repair, and remove concrete sections for demolition purposes

In general, a stationary contour cutting saw is used with carbon saw bands for either straight or controur cutting of non-ferrous metals as well as wood products and other materials