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7 Benefits of Choosing Surya Electric Flying Cold Saw Systems

Cutting is one crucial process in tube and pipe making that has significant impact on the product quality. Sometimes, even if a tube is formed and welded properly, it may have uneven lengths, rough edges and too many burrs that result in problems when it is handled and worked further. Delay can also impact the entire output of production.

In high-speed tube mills, the choice of cutting equipment is an important consideration for manufacturers. For smaller production volumes a conventional cutting arrangement can be used but in a continuous manufacturing line a cutting system must be able to follow the flow of the material.

This is where a Flying Cold Saw System comes in handy. It can be synchronized with the movement of the tube during the tube traveling along the production line so that cutting operations can be performed without stopping the overall production line for each cutting operation.

Surya Electric supplies flying cold saw systems for tube and pipe production processes. In this blog, we will talk about seven practical advantages of the selection of such systems and what factors manufacturers need to take into account before buying the one.

What Is a Flying Cold Saw System?

A flying cold saw is an industrial saw that cuts continuously moving tubes or pipes into desired lengths. On the cutting cycle, the saw moves with the moving tube, makes the cut and goes back to the starting point for the next cycle.

In contrast to a system, which must stop the production line every time a cut is required, a flying saw can keep the upstream process going. This is applicable for ERW tube mills and other continuous tube production lines.

Cold sawing is not a thermal process, instead this process involves a rotating saw blade. Cutting outcome will be dependent on blade selection, tube material, wall thickness, machine settings and maintenance.

1. Assists in keeping production moving forward

A major benefit of a flying cold saw is that it can be used to cut moving tubes without the need for the production line to stop for every cut.

Stopping and re-starting a tube mill repeatedly may result in a loss of production and cause a manufacturing interruptions. A synchronized cutting system can minimize these breaks by synchronizing the cutting speed with the speed of the tube.

This can be beneficial for manufacturers who make a significant amount of tubes, as it can help to alleviate bottlenecks in the cutting process and ensure that the production process flows smoothly.

Selected models of flying cold saws from Surya Electric have a maximum line speed of 120 metres per minute. Operating speed is selected based on machine configuration, tube dimensions, material and production conditions.

Prior to the choice of a model, determine if the operating range fits your tube mill's actual applications.

2. Helps Maintain Consistent Tube Lengths

Length accuracy is paramount to the customers who rely on finished tubes for fabrication, assembly, construction and other manufacturing applications. Different size can cause inserting problems, loss of material and extra rework.

A flying cold saw is a cutting device that cuts tubes based on the required dimensions with the help of length settings and synchronous motion. One of Surya Electric's product features is automatic length programming, which assist operators to handle different cutting requirements.

But machine setup, calibration, material movement and maintenance are also critical to achieving accurate length. Before the equipment is finalized, manufacturers need to communicate the tolerance that they require from the supplier.

If different batches of customers' orders are processed in the same business, an appropriate automatic cutting system can be used to facilitate the management of production.

3. Produces Clean Cuts With Less Burr Formation

The Quality of a cut tube end is important, particularly when the product has to be directly conveyed to packaging or another manufacturing process. Burrs and uneven edges may need further processing and labour.

With proper adjustment and operation, clean square cuts can be achieved with minimum burr formation on a properly adjusted cold saw. This can help to minimize the need for manual finishing and enhance the final product's appearance.

According to Surya Electric, their flying cold saw systems offer almost burr free cutting. Actual results will vary with the material of the tube, its thickness, blade condition and machine settings.

When choosing a cutting machine, ask questions about the types of blades offered, the quality of cuts you can expect for your type of material and what maintenance will be needed to ensure that the cutting is consistent. With a satisfactory cutting system, the operator should be careful of finished tubes as their edges can be sharp.

4. High speed tube production capability

The more demand there is for a tube, the more equipment is required to start and finish the tube forming and welding lines. The cutting machine may be a bottleneck if it is not capable of the desired production.

A flying cold saw can be used to achieve higher-speed production provided it is properly selected and synchronized with the continuous tube-feed. This makes the cutting stage more effective integration with the other parts of the mill.

The selected models on Surya Electric have up to 120 metres per minute rates. This is a maximum published value, and will not be guaranteed for all tube sizes and cutting lengths.

Cutting cycle, material characteristics, wall thickness and tube diameter may affect the production speed to be achieved. Therefore, it is preferable that manufacturers consider the full production need, instead of just the maximum speed.

5. Supports various tube sizes and shapes

Often tube manufacturers are ordered to make different diameters, thicknesses and profiles. The cutting system should be appropriate for the types of products being produced.

Surya Electric has a range of flying cold saw models available, which have varying tube size and thickness. Here are some examples of published specifications:

- **SE-FCS-01:** Tube outside diameters from 12.7 mm to 50.8 mm, with thicknesses from 0.8 mm to 3.0 mm.

- **SE-FCS-02:** Tube outside diameters from 19.05 mm to 88.9 mm, with thicknesses from 1.0 mm to 4.0 mm.

- **SE-FCS-03:** Tube outside diameters from 25.4 mm to 115 mm, with thicknesses from 1.2 mm to 5.0 mm.

The ranges in this document are subject to change and should be verified against the most up-to-date product specifications before ordering.

If your factory produces several tube sizes, consult with the supplier on the procedures required to change over, the tooling needed, and appropriate operating conditions. Choosing the right model can help prevent production restrictions due to changes in your product line.

6. Makes Routine Maintenance More Manageable

To ensure good working condition, maintenance of an industrial cutting machine should be done regularly. Inspection and replacement of the saw blade, in particular, are important to consider, as it directly impacts cutting quality.

A dull or damaged blade can result in poor finishes and higher machine loading and production downtime. Routine maintenance points that are easily accessible can then make a difference to the day to day activities.

Surya Electric mentions a quick blade changing system as a feature of its flying cold saw systems. Ball screws and ball slides for low-maintenance operation are also mentioned on its product information.

Actual maintenance needs will vary based on production volume, material, operating conditions and manufacturer's recommendations.

Find out the details before buying a machine: blade replacement, spare parts, blade inspection schedule, operator training, and technical support. These are the factors that will give you an idea of the operating cost in the long run, rather than simply the cost of purchase.

7. Consistent with ERW Tube Mill Production Lines

The flying cold saw must operate synchronously with the other production process of tubes. The ERW tube mill process involves the strip of metal being formed into a tube, the edges of the metal being welded, the tube going through subsequent equipment on the downstream side, and the tube being cut to length.

The cutting system should be parallel to the upstream process in regard to the movement and output of the process. A suitable flying cold saw can assist the cutting part to move in sync with the mill, and minimize production stops due to cutting.

Surya Electric offers tube mill equipment along with flying cold saw systems, which makes their product line suitable for manufacturers looking to ramp up a new tube mill or upgrade their existing equipment.

Discuss line speed, tube sizes, cut lengths, controls, floor space and integration requirements before choosing a machine.

See Surya Electric's [Flying Cold Saw Systems] and [Mild Steel Tube Mills] to view the equipment available.

How to Choose the Right Flying Cold Saw Machine

It's not just the speed to consider when making the right machine choice; it's your production needs. When shopping, take the following into account:

- **Tube dimensions:** Check for the supported diameter, wall thickness and profile range.

- Production speed: Make sure that the machine runs at the same speed and production as your mill.

- **Cutting accuracy:** Discuss tube lengths and tolerances with supplier.

Check if the machine and the blade are suitable to your material specifications.

- Maintenance: Discuss blade replacement, change over time, spare parts and routine maintenance.

- Technical support: Inquire into set up, training for users and follow-up support.

If you know you want to use these points, you can make sure you will have the right equipment for the real production.

Surya Electric Flying Cold Saw Systems can be a valuable addition to your hard maintenance toolbox.

Tube manufacturers require a cutting machine to provide more than speed. Standard length, clean cut ends, ease of maintenance and ease of production line compatibility are also important.

The flying cold saw range offered by Surya Electric comprises of a variety of models to cut different tube sizes and thicknesses. The features listed above include blade changing mechanism, touch-panel control, automatic length programming and synchronized flying cutting.

These are features to consider when upgrading the cutting section of an existing ERW tube mill or when considering a new production line.

This will be determined by your tube size, the speed of the mill, the required tube lengths and the quality standards. Providing this information to the supplier will enable them to suggest the most appropriate model for your application.

Frequently Asked Questions

1. A flying cold saw is used for what?

It is a cutting machine that can cut the continuous moving tubes or pipes into lengths without stopping the whole production line for each cut. It is widely applied in tube mills and in continuous manufacturing processes.

2. What is the main advantage of a flying cold saw?

The primary benefit is the simultaneous cutting along with the movement of the tube. This can minimize production downtime and help maintain production.

3. Are there burr-free cuts with a flying cold saw?

With proper configurations, it is possible to make clean cuts with minimal burrs. The results will vary based upon the material, condition of the blades, machine settings and machine maintenance.

4. What is the highest speed of Surya Electric Flying Cold Saw Systems?

Some specifications give a maximum speed of up to 120 metres per minute for certain models. Actual performance may vary depending on model and production conditions.

5. What is the best model to choose?

Establish a comparison between the diameter and thickness range of the model and Production. Take note of line speed, material type, cutting accuracy, maintenance and the ability to integrate the line with existing equipment.

Conclusion

The cutting stage of tube and pipe production can be enhanced by use of a flying cold saw system which cuts the moving material in sync with the production line. This can minimize interruptions, keep lengths constant, aid in high-speed cutting, and create clean cut ends.

Surya Electric Flying Cold Saw Systems are available in various models and features to address various tube production needs. Prior to choosing, check the technical specifications, and talk with the supplier regarding your tube size, wall thickness, speed of production and cutting needs.

When selecting a cutting system, you can ensure that your factory has a more efficient and reliable manufacturing process.