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THE ORANGE BOOKA bandsaw guide by BAHCO

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Welcome to the Bahco Bandsaw Guide.

We are proud to present you this user guide that can help you to provide

the lowest cost per cut.

Quality is our number 1 priority and we believe that the key success factor

in both production and general purpose cutting is product consistency. To

achieve this, we developed the Bahco Quality Forward System, a system

which uses the ISO 9001-200 framework.

We strive to continuously improve our quality management system focus-

ing on customer needs and satisfaction. Rapid Continuous Improvement

is fundamental to our production processes where we believe in continu-

ously improving our products everyday.

D = y + φ (x º / d2) D = y + φ (x º / d2)D = y + φ (x º / d2)

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D = y + φ (x º / d2) D = y + φ (x º / d2)D = y + φ (x º / d2) D = y + φ (x º / d2)

TERMINOLOGY

Types of SetThe set is the tilt, or angle, given to the teeth of the saw blade to provide clearance for the blade body and the tooth edges. Below are different types of set:

Raker SetIn the raker set, one tooth is set to the left, one tooth is set to the right, and one tooth (raker) is unset. This set type is used on most evenly pitched blades such as regular and hook. It is also used for contour and friction cutting blades on vertical bandsaw machines.

Combo SetIn the combo set, used on combo toothed blades, a raker (unset) tooth is followed by teeth in a left, right, left, right sequence. This pattern is repeated with each series of teeth starting and ending with the largest tooth in the pattern.

t

h

b

w

s

α

b: width of blades: thickness of bladeh: gullet deptht: tooth pitchα: rake angleγ: clearance anglew: width of set


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MachineWhat machine are you using? Brand name, brand type and machine type. The right blade dimensions depend on the used machine.

Other needs Besides the machine specifications it is very important to check the condition of the machine. It is important to check the condition of the wheels, guides, chip brush and coolant.

Material

4. Install the blade

1. Analyse application

?

3. Determine TPI

2. Determine the product

1. Analyse Application

Multi layer profiles

Round bar

Bundle multi-layer

Bundle of round bars

Beams

Bundle of tubes

Special profiles

Square bar

Tube

Flat bar

HOW TO SELECT YOUR BLADE?

5. Run the blade

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D = y + φ (x º / d2) D = y + φ (x º / d2)D = y + φ (x º / d2)D = y + φ (x º / d2)D = y + φ (x º / d2) D = y + φ (x º / d2)


2. Determine the product Bi-Metal or Carbide?

Bi-metal Blades High-speed steel tooth tips, combined with flexible alloy-steel backing material results in the most cost effective bandsaw blades for most metal sawing applications.Bi-metal bandsaw blades cover most market requirements, including multi-purpose blades and contour cutting, cutting tubes and profiles, foundry cutting and production cutting.The Sandflex® bandsaw blades cut different types of steel (structural, machining, quenched, tempered, high speed, nitriding) as well as brass, copper, nickel, cast iron, titanium and many other materials.

Carbide Blades Bahco produces a comprehensive range of set and unset carbide bandsaw blades to ensure that we can meet the demands of our production cutting customers.High performance backing steel and optimized carbide grades give premium bandsawing performance. These products will cut faster and last longer than any other bandsaw blade in a wide variety of sawing applications. The blades are designed and produced for high efficiency cutting of difficult and abrasive materials as well as high performance cutting of large and difficult to cut workpieces.

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3. Determine TPI?

mminch

Example 1

Example 2

Tooth pitch for solid workpiecesThe diagram will help you to select the right pitch for cutting solids. The ideal choice is at the widest point of each field.Example 1: When cutting a Ø 150 mm (6 inch) bar, use a 2/3 TPI or a 1.4/2 TPI if you choose a variably pitched blade. Use 2 TPI, if an evenly pitched blade is your choice. Example 2: If you are sawing in soft materials like plastics, aluminium or wood, choose a pitch two steps coarser than recommended.When cutting 13-20 mm (1/2-3/4 inch) thick pieces of aluminium, use a 5/8 TPI or a 6 TPI blade.

Cutting pipes and profilesThe diagram will help you find the correct tooth pitch for cutting pipes and profiles. The recommended tooth pitch for cutting profiles is found in the field where the width meets the wall thickness of the profile.Example 3: When cutting a 100 x 10 mm (4 inch x 0.4 inch) U-beam, select a 5/8 TPI or a 4/6 TPI blade. The recommended tooth pitch is found in the field where the outer diameter meets the wall thickness of the pipe to be cut.Example 4: When cutting a 40 x 1.6 mm (1.5 inch x 0.06 inch) pipe, select a 10/14 TPI blade.

inch

Example 3

Example 4

mm inch

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EASY-CUTChoose S (Small), M (Medium) or L (Large), depending on the cutting range you need.

Table of RadiusBand Width:The band width is measured from the tip of the teeth to the back edge of the blade.On horizontal machines, the band width is dependent upon the bandsaw machine being used. There is, however, some variation possible on vertical machines.For contour sawing, the blade should be as wide as the machine permits, but still narrow enough so that it can cut the desired shape. Please see diagram.

Min

imum

radi

us

mminch

1 2 3 5 10 20 30 40 50 75 100 150 200Material Size (mm)Order Code Blade Size

Width x Thickness

Within any size range Small = Good surface finish Medium = Good band life Large = Speed of cut

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1. 2. 3.

Feed Rate/ChipsIt is important that each tooth of the bandsaw blade cuts a chip with the right thickness. This is determined by the selection of tooth pitch, band speed and feed rate. You can now set the correct feed rate by studying the chips which the bandsaw blade produces when cutting. Use the pictures (below) and adjust your feed rate or band speed accordingly.For more information on cutting data contact your local Bahco representative who can help you find the correct cutting data for your specific application.1. Thin or pulverised chips: increase feed rate or lower band speed2. Loosely rolled chips: correct cutting data3. Thick, heavy or blue chips: too high feed, lower feed rate or increase band speed

Teeth Per Inch (TPI)The number of teeth per inch (TPI) defines the pitch of the blade and can vary from less than 1 to 24.Thin-walled workpieces like tubes, pipes and sheet require fine teeth, otherwise there is a risk of tooth damage or breakage.Large cross sections should be cut with a coarse-pitched saw, i.e. fewer teeth per inch. The fewer teeth engaged in the workpiece the higher the cutting capacity. This is because the penetration capacity of each individual tooth is greater if the saw’s feed pressure is distributed over a lower number of teeth. A coarse pitch (few TPI) therefore increases productivity and provides a desirable, large chip space.Soft materials, such as aluminium and bronze require a large chip space. A coarse pitch prevents the chips from building up and packing together in the gullets, which can impair sawing and damage the blade.

1 2 3 4

1”4 TPI


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D = y + φ (x º / d2) D = y + φ (x º / d2)D = y + φ (x º / d2)D = y + φ (x º / d2)D = y + φ (x º / d2) D = y + φ (x º / d2)4. Install the blade

5. Run the blade

MachineCheck frequently:• The operation of the chip brush• The wear and alignment of the

guides• The band tension with a tensionmeter• The band speed with a tachometer• The coolant concentration with a

refractometer

Coolant / Cutting fluidThe coolant lubricates, cools and carries the chips from the cut. It is important to:• Use appropiate cutting fluid• Use recommended concentration of

cutting fluid

• Make sure that the cutting fluid reaches the cut with low pressure and large flow

Workpiece• Make sure that the workpiece is

firmly clamped so that it cannot vibrate or rotate

• Do not use bent or damaged workpieces

Tooth protector• Keep the tooth protector on the

blade until it is mounted on the machine to avoid premature chipping of the tooth tips


Bi-metal blades: To obtain the maximum blade life always use the recom-mended band speed but lower the feed rate to 1/3-1/2 during the first 10 minutes of cutting. During the next 10 minutes increase the feed rate in stages, until you have reached the recommended feed rate.Carbide blades: Other running in procedure is needed. Contact our bandsaw specialist for assistance with this procedure.

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Material 10-65 100-300 400-800 >1000 COOLANT

1 Structural steels, machining steel 100 85-95 60-75 40-60 6%

2 Structural steels, quenched and tempered steels 80 70-80 60-68 40-50 6%

3 Case hardened, spring steels, quenched and tempered steels 75-100 60-80 45-65 30-40 8%

4 Unalloyed tool steel, ball and roller bearing steel 60-65 55-60 35-45 25-35 8%

5 High speed steel 45-50 40-45 30-35 20-25 8%

6 Cold work tool steel 30-35 25-30 20-25 15-20 DRY

7 Tool steels, alloyed 45-65 45-60 40-60 20-40 8%

8 Nitriding steels, high alloyed hot working steels 40-45 35-40 25-30 20-25 8%

9 Cast iron 50-60 45-50 30-40 25-30 DRY

10 Rust and acid-resistant steels (light) 40-45 40-45 35-40 30-40 10%

11 Rust and acid-resistant steels (heavy) 35-40 30-35 20-30 19-22 10%

12 Duplex and heat resistant steels 25-30 20-25 15-20 14-16 10%

13 Nickel and nickel-cobalt alloys 15-20 13-15 10-12 10 10%

14 Titanium, titanium alloys; aluminium bronze 30-35 25-30 20-25 16-18 10%

15 Horizontal machines, aluminium, aluminium alloys 120 120 120 120 25%

16 Vertical machines, aluminium, aluminium alloys 3000 2100-2500 1250-2000 500-1200 25%

17 Brass 120 120 90-120 80-100 4%

18 Copper 120 110 80-100 60-80 15%

Material 10-65 100-300 400-800 >1000 COOLANT

1 Structural steels, machining steel 200 160-190 110-150 60-90 12%

2 Structural steels, quenched and tempered steels 140 120-140 85-115 50-70 12%

3 Case hardened-, spring steels, quenched and tempered steels 120-130 110-120 75-110 40-60 10%

4 Unalloyed tool steel, ball and roller bearing steel 100-120 90-100 60-90 40-50 10%

5 High speed steel 100-110 80-90 60-75 50-60 10%

6 Cold work tool steel 80-100 60-90 60-75 45-65 DRY

7 Tool steels, alloyed 85-95 80-90 60-70 50-60 8%

8 Nitriding steels, high alloyed hot working steels 75-85 70-80 60-70 45-60 8%

9 Cast iron 90-105 90-95 60-75 40-55 12%

10 Rust and acid-resistant steels (light) 80-110 80-100 70-95 65-80 12%

11 Rust and acid-resistant steels (heavy) 80-90 70-80 60-70 40-50 13%

12 Duplex and heat resistant steels 100-115 80-100 65-80 50-60 12%

13 Nickel and nickel-cobalt alloys 30-40 25-30 20-28 15-20 12%

14 Titanium, titanium alloys; aluminium bronze 50-60 40-50 35-45 16-18 12%

15 Horizontal machines, aluminium, aluminium alloys 250 250 250 250 25%

16 Vertical machines, aluminium, aluminium alloys 5000 4000-5000 3000-4000 2000-3000 25%

17 Brass 250 250 180-240 140-160 4%

18 Copper 240 220 130-190 100-120 15%

Bi-metal

Carbide

The bigger the size, the lower the speed

Meters per minute at Ø mm

SPEED SELECTION

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CHIPLOAD CALCULATION

Cutting performance The best way to control the cutting performance is to calculate the feed per tooth. To find the optimum feed per tooth we use a formula.

fh Feed / Tooth (mm)h Height of workpiece (mm)TPI Average tooth pitch (TPI)t Cutting time (min)v Band speed (m/min)

Example

200 mm dia.TPI used 2/3Band speed 40 MPMCut time 10 min

Optimum feed / tooth

Inconel .0025 mm (.000094”)Tool steels .0035 mm (.00013”)Stainless steels / Titanium .0050 mm (.00020”)Low alloys / Alloy steel .0080 mm (.00031”)Bronze / Copper / Aluminium .0120 mm (.00047”)

Feed per tooth will vary with: - blade width - size of workpiece

40 is a constant, because there are about 40 inches in one meter.

Feed / Tooth

fh=

200 mm40 2.5 10 40

º .005 mm

Constant Average TPI Cut time Band speed

h

40 x TPI x t x v

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12 POINT INSPECTION

1. Chip brush

Items checked / procedure

Check the condition of the chip brush. Replace when needed.

Problems Caused

Tooth breakage, rough cutting and premature wear of tooth.

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12 POINT INSPECTION

2. Blade tension


Measure tension with a tension meter and record the measurement. The correct tension for both carbide and bi-metal blades should be between 250 en 330 N/mm2, depending on the size of the blade and machine type.

Problems Caused

Blade breakage, crooked cutting, vibration and slippage between the band and the wheel.

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12 POINT INSPECTION

3. Blade speed


Verify operation of band speed controls and speed indicators.

Problems Caused

Tooth damage, crooked cutting, premature tooth wear.

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12 POINT INSPECTION

4. Machine feed


Down feed is measured in mm/min.If the machine does not have a reading you can measure it yourself.See how far the head drops in 1 minute.It is useful to put a magnet on the column and measure there.

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12 POINT INSPECTION

5. Coolant flow


Verify coolant flow from all hoses and ports. Check coolant concentration with a refractometer. We recommend a 7% for Bi-metal and 10% for Carbide concentration minimum.

Problems Caused

Premature tooth wear, tooth breakage and crooked cutting.

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12 POINT INSPECTION

6. Guides


Disassemble guides, check for cracks and/or chips. Carbide guide surface should be higher than surface of the steel holder. Look for excessive wear on the corners of the carbides.

Bearing type guides should be checked for looseness between the centre shaft or post and outer bearing surface. Make sure the bearings turn freely.

Problems Caused

Band breakage, crooked cuts, blade vibration.Tight roller guides will pull the blade off the idler wheel. Blade should slip freely between guide rollers.

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12 POINT INSPECTION

7. Blade tracking


Inspect the band position on the band wheels, the blade must not touch the wheel flange. The blade should be positioned in a way that the largest portion of the blade body is supported by the wheel surface.

Problems Caused

Blade breakage and/or cracking. Crooked cutting, caused by set damage or blade twist. Wheel damage of flange wear.

Place your business card between the band and the wheel and make a turn. If the card is cut, the blade touches the flange.

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12 POINT INSPECTION

8. Wheel bearings (general check wheels)


Inspect for flat spots on the wheel surfaces.Rock wheels side to side for bearing play.

Problems Caused

Band breakage, blade slip.

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12 POINT INSPECTION

9. Stock feed and clamping system


Verify correct sequence of stock feed system making sure blade is clear of stock during auto feed cycle.

Problems Caused

Blade breakage and or tooth damage.

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12 POINT INSPECTION


Verify condition and operation of saw clamp and feed clamps, list problems found.

Problems Caused

Tooth damage, crooked cutting, blade breakage.

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12 POINT INSPECTION

10. Drive Mechanism


Check condition of all drive belts. List all fluid leaks in drive gear box. Report all unusual gear of bearing sounds. Check for smooth running of all parts.

Problems Caused

Tooth damage, crooked cutting.

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12 POINT INSPECTION

11. Hydraulic fluid levels


Check hydraulic fluid level. Check oil level in all air oilers. Check gearbox oil level.

Problems Caused

Erratic operation of saw arm. Wrong blade tension. Erratic blade speed control.

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12 POINT INSPECTION

12. Lubrication (Nipples)


Check lubrication. These need to be filled with lube oil.

Problems Caused

Erratic operation of saw arm, bridge, guides or other parts of the sawing machine that need to be lubricated.

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SAFETY

Safety is important and suitable protective clothing should be worn at all times in the working place.

The cutting of materials can cause eye injuries by flakes or splinters. A damaged eye can never be replaced!

ALWAYS wear eye protection.

FOLDING BANDSAWS

FOLDING 3

FOLDING 4 FOLDING 5Twisted wire for securing

the saw

FOLDING 1

FOLDING 2

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UNFOLDING BANDSAWS UNFOLDING 1 UNFOLDING 2

UNFOLDING 3

Unfolding large bandsaws

UNFOLDING 1

UNFOLDING 4

UNFOLDING 2

UNFOLDING 5

UNFOLDING 3

UNFOLDING 6

UNFOLDING 5 UNFOLDING 6

UNFOLDING 4

Release this hand cautiously

SAFETY

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TIPS & TRICKS

1. Remove the tooth protector when blade is on the machine

Many operators remove the tooth protector before the blade is on. Even with Carbide.

This is not recommended because if the teeth get damaged, blade life decreases significantly and the blade needs early replacement. The guards are used as a safety precaution.

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TIPS & TRICKS

2. Old cut

Never start cutting in an “old” cut. The saw blade could be damaged from hitting hidden teeth from previous bandsaw.

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TIPS & TRICKS

3. Chip brush

Chips at the side of entrance of the band indicate that the chip-brush is not working properly.Check and correct as soon as possible.

This can cause:tooth breakagerapid tooth wear

Cutting direction

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D = y + φ (x º / d2) D = y + φ (x º / d2)D = y + φ (x º / d2)D = y + φ (x º / d2)D = y + φ (x º / d2) D = y + φ (x º / d2) 4. Driving unit

The cutting direction is important.The loop is not always delivered in the correct direction for the machine.It is a simple process to turn the blade around.Cutting direction is normally towards the motor.

FRONT OF TOOTH

TIPS & TRICKS

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TIPS & TRICKS

5. Chips

Checking the chips is a good tool to judge how the blade is cutting.Look at shape and colour.If you keep chips aside of several stages during the trial, you can see the effect of changing parameters during the cuts.

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TIPS & TRICKS

6. Bundle cutting

Very tricky as the bars can move or spin.Especially on smooth, round bars.Welding the ends together prevents this.

Moving workpieces can cause tooth- and even band-breakage.

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TIPS & TRICKS

7. Cutting materials with stress

Internal stresses can make the material to “bind-in” causing the blade to break (This often happens in forges).By using a wedge, you can prevent this.

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TIPS & TRICKS

8. Tool steels

Tool steels are often cut dry (D-2, D-3, D-4, D-7).Still some operators swear that a light lubrication makes the cutting job easier.

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BANDCALC

BandCalc on CD and iPad

BandcalcTM also allows Bahco bandsaw users to:

- Identify the time per cut - Calculate the cost of each cut in

their machine - Compare different results

between different Bahco blades

THE APPLICATION WILL GIVE YOU THE RECOMMENDED BAHCO BLADE AND PARAMETERS

Bandcalc for the iPad is available from the App store 1. SELECT THE BANDSAW MACHINE Machine condition, band width, thickness and length

2. SELECT MATERIAL TO CUT

3. SELECT WORKPIECE DIMENSIONS Type, dimensions, surface and type of bundle

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BANDBREAKAGES

Back edge damage

Result

Lip on Back Edge

Cause

Worn or damaged machine guidesExcess feed force

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BANDBREAKAGES

Back edge damage

Result

Damage to Back edge

Cause

Worn or damaged machine guides

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BANDBREAKAGES

Side damage

Result

Machine guide arms out of alignment

Cause

Excess machine guide pressure

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BANDBREAKAGES

Side damage complaint - Band breakage

Result

Guide mark present on one side of the blade

Cause

Guide fault

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BANDBREAKAGES

Side damage complaint - Band breakage

Result

Same band with after a slight bend test

Cause

Guide fault

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BANDBREAKAGES

Fatigued due to excess tension

Result

A crack will follow the shortest possible route unless influenced by excess tension

Cause

Too high tension

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TOOTH TIP FAILURE

Poor life

Result

Excess heat generation on tooth tipsBlue discolouration

Cause

Excess feeds or speedsPoor coolant

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TOOTH TIP FAILURE

Misuse

Result

Twisted blade

Cause

Too high tension on one side of the guides

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TOOTH TIP FAILURE

Cutting chips welded to tooth tips

Result

Excess feeds or speedsChip brush not working

Cause

Poor coolantTooth pitch too fine

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TOOTH TIP FAILURE

Tooth strippage

Result

Excess feeds or speedsChip brush not working

Cause

Poor coolantTooth pitch too fineIncorrect break-inWorkpiece not secure

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PERFORMANCE FAILURE

Crooked cutting

Result

Cutting out of square

Cause

Guides too far apartLow band tensionExcess feed

Tooth pitch too fineDamaged teethBand worn out

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NOTES

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NOTES

48


NOTES

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NOTES

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D = y + φ (x º / d2) D = y + φ (x º / d2)

NOTES

Be Sharp, Use Bahco Bandsaws

the orange book - vallen · 1 2 3 5 1020 30 5040 75100 150 200 order code blade size material size...

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