To ensure the thickness consistency of TCT saw blades, high-precision control needs to be implemented throughout the entire process, from raw material management and processing technology to factory inspection. The core control methods are as follows:
1. Controlling Raw Material Consistency from the Source
Prioritize using steel plates rolled in the same batch as the base material: The thickness uniformity error of steel in the same batch can be controlled within 0.02mm, avoiding thickness deviations between different batches of raw materials.
Carbide cutter heads adopt molding pre-forming + pre-sintering treatment: After pre-sintering, the cutter head thickness is screened, and blanks with excessive thickness are discarded to ensure that the initial thickness error of all cutter heads in the same saw blade is ≤0.03mm.
2. Precise tolerance control and step-by-step tolerance reduction in processing:
(1) High-precision grinding of the substrate: A CNC gantry surface grinder is used for multi-pass grinding. The feed rate for each grinding pass is controlled at 0.01-0.03 mm. During processing, an online micrometer is used to monitor the thickness in real time. After grinding, the flatness and thickness difference are checked overall. Only when the substrate thickness tolerance is ≤0.05 mm can the next process begin.
(2) Post-welding grinding and calibration of the cutter head: After the cutter head is brazed, both sides of the cutter head are simultaneously precision ground using a CNC gear grinding machine. This forces calibration of the thickness of all saw teeth on the same piece, ensuring that the overall saw tooth thickness consistency tolerance is ≤0.02 mm. If a wear-resistant coating is required, a coating thickness allowance is reserved in advance (generally 0.02-0.04 mm) to avoid exceeding the tolerance after coating deposition.
(3) Stress Relief and Deformation Correction: Both substrate grinding and blade welding generate internal stress. This stress needs to be relieved through thermal aging or vibration aging processes to prevent deformation of the saw blade after processing, ensuring consistent thickness for long-term use.
3. Complete Finished Product Inspection and Screening to Guarantee Factory Qualification Rate:
Multi-point thickness testing is employed: 8-12 measurement points are evenly selected on the saw blade end face, and the thickness is measured one by one. Any saw blade with a thickness difference exceeding the corresponding product tolerance standard is scrapped.
Synchronous Dynamic Balancing Verification: Uneven thickness can lead to dynamic balance deviations. Thickness is simultaneously recalibrated during dynamic balancing to avoid missed detections of localized deviations.
Industry-Standardized Qualification Standards: For ordinary woodworking/aluminum cutting TCT saw blades, the maximum thickness deviation of the entire saw blade must be controlled within 0.05mm. High-precision industrial cutting saw blades require a deviation ≤0.03mm. Meeting these standards ensures dimensional stability during the cutting process.
