Guaranteeing modularity is a declared aim – and that goes not only for the development of small bandsaw models, but also the very biggest machines of the range. Whether a table-top variant, a model with roller support, or a gantry design – the new large-scale bandsaw generation from BEHRINGER leads the field. The company is also focusing on the innovative vertical ring saws based on the LPS models.

The new-generation large bandsaws from BEHRINGER are based on the modular design principle, allowing users from wide-ranging sectors such as forging companies, steel producers, rolling mills, mould builders or steel trading companies to machine heavy, cumbersome materials quickly and precisely. Tolerances of just 0.1 mm per 100 millimetres cutting height are easily possible.

A high proportion of identical components ensures a significantly faster production and assembly throughput time, helping to cut delivery periods. By standardizing components, the new large bandsaw series opens up scope for non-standard solutions in line with customer specification. Because of its impressive production depth, the manufacturer from Baden-Württemberg in Southwest Germany guarantees optimum workmanship, a stable design, reliability and durability. Its large bandsaws, which generally work around the clock in three-shift operation, rely particularly on precisely these characteristics. Because it runs its own in-house foundry, Behringer GmbH provides everything from the smelted iron through to the finished machine from a single source.

Roller support, table support or gantry model

The large bandsaws come with precise saw feed provided by two ball screws with servo drive. The axes are electrically coupled and constant chip removal is guaranteed even at low feed rates. The result: a perfect and precise cut.

A gantry machine, whose entire saw frame is moved on linear guides over the workpiece, is not only the most technically complex solution but also requires the least space. It is predominantly suited for users who need to divide freeform forgings or large solid forged parts. The fixed support table is able to cope with extreme loads, in some cases over 100 tons depending on the machine version. Adjustable prism supports permit simple centric workpiece alignment.

The variant with table support is the ideal all-rounder in forges, rolling mills and gravity die casting foundries, and also for steel finishing applications as well as tool and mould making. The independently movable vices and guide arms makes it ideal for sawing cumbersome materials. The low table height facilitates set-up of the machine on the normal hall floor level. Their stabile design makes these machines ideal for use in rough industrial environments, as the rugged tables are capable of withstanding extreme loads, and the guides are insensitive to dirt.

Large bandsaws with roller support (roller conveyor) are highly suitable for dividing large pipes or round and rectangular material, and are used predominantly by the steel trade.

One of the interesting design features of BEHRINGER large bandsaws is their gantry machine design, which guarantees optimum stability during the sawing process. It ensures quiet, smooth-running saw blades, prevents torsion and minimizes vibration during sawing processes. All band guiding components are made of vibration-damping grey cast iron. This not only ensures better care of the saw blades, but also makes for a quieter cut. The open design helps improve access to the machine to change saw blades or for maintenance work.

Useful facilities for improved upstream and downstream material handling:

There is plenty that can be done to enhance safety for operating staff and ensure better alignment prior to cutting, right from the moment these multi-ton workpieces are placed in storage. The table version with T-slots has proven highly successful in practical application over many years for the individual positioning of fixtures and clamping elements for sawing workpieces such as rectangular materials. For round material with a high diameter, prism supports are suitable, as they ensure central alignment of the material on the table and simplify the safe support of heavy parts. These are also arranged flexibly in the existing T-slots of the material table.

A special laying flat fixture provides a valuable material handling aid for the table models. Heavy offcuts are engaged and laid flat in a controlled process after cutting. This enhances operator safety and offers a significant handling benefit during transport out of the machine.

Innovative – the LPS ring saw for large pipes

Large metal pre-turned, rolled or forged rings, some of them in high-strength materials, are in demand across numerous branches of industry. End uses for this type of product include wind power plants or turbine bearings. The rings are manufactured by parting off from large forged pipes. However, during classical turning operations, a large volume of material is lost through the tool due to the wide gap. This is in direct contrast to classical sawing processes, where more good parts can be sawn from the starting material due to the significantly lower cutting gap. A special-purpose machine innovated by saw manufacturer Behringer also opens up enormous potential for savings for customers wishing to divide rings from pipe sections. The trick: the sawn rings are automatically deposited on a mandrel, so allowing unmanned operation over a period of several hours. This collecting fixture is designed to be fed forward to engage the cut rings in such a way that the offcuts cannot collide with the bandsaw blade. The face plate with chuck on which the pipes are clamped on the infeed side moves in counter-rotation to the saw blade, ensuring optimum sawing performance. After a retooling process taking just 15 minutes, the next pipe can be fed into the machine in a new clamping operation and – depending on the material – the LPS can continue to operate unmanned for a number of hours in automatic mode. This makes the perfect ratio of tooling time to machining time.