Experimental investigation of cutting performance for circular saw blade body modification by resin layers toward green manufacturing

Cemented carbide circular saw blades are widely used in the metal and nonmetal manufacturing industry for cut-off and cut-tail production. High energy consumption and intense noise emission from conventional-type blades are urgent environmental issues to be solved. Hence, a laminated-resin blade is proposed to study the effect of adding a damping structure to the blade body on its cutting performance. Apart from reduced energy consumption, lower noise and high-quality surfaces are required by manufacturers. In this work, a laminated-resin blade and a conventional blade were compared regarding the details of cutting force and energy consumption, noise emission, and surface integrity. In addition, the effect of cutting fluid on conventional saw blades was analyzed in terms of cutting force and noise emission. Experimental results show that the cutting force and noise of the laminated-resin blade were less than that of the conventional one, indicating reductions of 27.8% and 18 dB, respectively. Especially a reduction of more than 20 dB sound level was achieved in the high-frequency band. Lower cutting force attained by the laminated-resin blade showed that smoother cuts could be achieved. Cutting with cutting fluid is superior to dry cutting in terms of cutting force, noise level, and workpiece surface integrity. The research sheds new light on the design of damping structures on saw blade bodies and quantitative analysis of the cutting performance.