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Bend Specimen Cutting System

The Fischer Engineering Company Model BSC Bend Specimen Cutting System consists of an indexing base (BSC-IB) and heavy-duty fixtures for high production cutting of bend specimens from welded plates and pipes. It can be mounted on several models of HEM, Hyd-Mech, Marvel and other vertical tilt band saws with 20” upper guide height. The preferred blade is 1-1/4 inch wide x 0.042 thick with a 3-4 or 2-3 variable pitch. 

The plate bend specimen cutting fixture can be used with some conventional vertical band saws that have at least 14″ upper guide height and hydraulic or air-driven table feed. The preferred blade is 1 inch wide x 0.035 thick with a 3-4 or 2-3 variable pitch. 

The Model BSC does not require any special exhaust or ventilation system. It also does not have the high noise level associated with systems using abrasive saws. 

The system is mounted on the front end of the saw worktable, within easy reach of the operator.  The system does not necessarily have to be removed to use the saw for other purposes, although the normal stock capacity may be reduced by as much as 50-67% if the system is left in place.

A Backing Bar Cutting Fixture (BBC), for cutting the excess backing bar material from plate face, root, or side bend specimens is also available. This fixture is not mounted on the BSC-IB, but held in the saw vise. The BBC can be used without removing the BSC-IB.

The photo shows the BSC-IB mounted on an HEM Model V100HLM-3 saw. The BSC-IB indexing base can be lifted into place or removed by two workers or by hoist. The BSC-IB is secured to the saw T-slots with 2-4 bolts. The individual plate or pipe fixtures are mounted on the indexing base with 2-3 bolts. The operator can interchange fixtures in a matter of minutes.

The photo shows the BSC-IB mounted on an HEM Model V100HLM-3 saw. The BSC-IB indexing base can be lifted into place or removed by two workers or by hoist. The BSC-IB is secured to the saw T-slots with 2-4 bolts. The individual plate or pipe fixtures are mounted on the indexing base with 2-3 bolts. The operator can interchange fixtures in a matter of minutes.

The operator also interchanges templates, attached by 2 screws, that control the cutting width of bend specimens and the distance between specimens.  Before using a new template he aligns the saw blade in a fixture slot and slides the template until the appropriate notch is engaged with the latching mechanism. He then tightens the 2 screws.

The home position and depth of cut is automatically controlled by the system if Fischer Engineering Company provides the saw. If the system is mounted on a manual customer-supplied saw, the customer will have to set up a method for controlling the home position and depth of cut.

Except on high-end, fully automatic saws, the operator controls both the advance and retraction of the blade. With the HEM Model V100HLM-3 automatic saw, the blade is started and advanced by a single switch. The blade retracts to the home position and stops automatically. On this saw, cutting time is about 3-5 minutes per bend for steel.

The main laborsaving advantage of this system is that the operator does not have to measure cutting distances or widths. During the time between cuts he can identify specimens to be cut from the next sample using a pen marker. Usually this is done before cutting since a coolant is used during cutting.

BEND SPECIMEN CUTTER

Select from the following lists. Not all items are required for a particular application. Start at the top and work downwards, picking only the items that apply.

BSC-IB
Indexer Base. One indexer base is required for each saw to be used as a bend specimen cutter. The type of saw or its T-slot dimensions must be specified at the time of order so that the correct mounting holes can be provided. Only certain vertical band saws are supported. The following fixtures can be interchangeably mounted on the BSC-IB.
$4,190.00

BSC-2
2″ Pipe Fixture. For cutting bend specimens from 2″ nominal and Super (2-3/4″ x 5/8″ wall) pipe size . Requires a set of Pipe Mandrels for each schedule of pipe to be cut.
$3,025.00

BSC-6
6″ Pipe Fixture. For cutting bend specimens from 6″ pipe. Requires a set of Pipe Mandrels for each schedule of pipe to be cut.
$4,250.00

BSC-1PLT
1″ Plate Fixture. For cutting bend specimens from samples up to 1″ thick x 8″ across the weld. Requires a plate template for the code, type of bend specimen, and thickness of saw blade to be used.
$3,570.00

Fixtures

Plate Fixtures

The BSC-1PLT  fixture can be used to cut bend specimens from welder performance test samples in accordance with ASME, AWS, and Military codes and standards. The clamp design can accommodate the warpage common in plate samples as well as taper from end to end. However,  the sample edges that are clamped must be straight. Saw-cut coupon edges are best. Flame-cut coupons that have irregularities or warpage will not work.  

Only moderate hand clamping is required to hold the sample in place. The upper jaw of the plate fixture is spring balanced for self-release when the clamps are loosened.  

Typical cutting time is 2-5 minutes per bend specimen. Indexing time is a matter of seconds.

Templates:

Templates are designed to meet specific codes and standards. The stocked part numbers are listed below and on the price list. Other special templates can be manufactured to order. All part numbers are designated by the BSC prefix followed by the code abbreviation, the bend specimen width, and the cutting blade width. The template dimensions include a factor to add approximately 0.020 inch to the specimen width for clean-up by grinding or sanding.

  • T-IX-3/8.042
  • T-IX-1-1/2.042
  • T-AWS-3/8.042
  • T-AWS-1-1/2.042
PIPE TEMPLATES

T-3/8.042
3/4″ Pipe Template. For cutting 3/4″ wide face and root bend specimens with a pipe fixture using an 0.042″ thick saw blade.
$105.00

T-1-1/2.042
1-1/2″ Pipe Template. For cutting 1-1/2″ wide face and root bend specimens with a pipe fixture using an 0.042″ thick saw blade.
$105.00

T-1-1/2.042
1-1/2″ Pipe Template. For cutting 1-1/2″ wide face and root bend specimens with a pipe fixture using an 0.042″ thick saw blade.
$105.00

Pipe Fixtures

The following pipe fixtures are presently available: 

  • BSC-2 – for 2 inch nominal (shown in the photo) and Super (2-3/4″ x 5/8″ wall) pipe size.
  • BSC-6 – for 6 inch nominal pipe size. 

Each fixture requires optional mandrels related to the pipe schedules to be accommodated. These are listed below.

Each fixture can be used to cut bend specimens from welder performance test samples in accordance with ASME, AWS, and Military codes and standards. The swivel clamp design can accommodate the warpage common in pipe samples. However,  the sample ends that are clamped must be flat. Saw-cut or turned coupon ends, with or without a bevel, are best. Flame-cut coupons ends that have irregularities or warpage will not work.  

Loading of individual fixtures requires only 1 wrench (for the clamp) at most. The upper fixture platen is adjustable so that samples from 6 to 9 inches long can be accommodated. The shorter the sample, the closer the tolerance on the width can be, and the faster the cut can be made.

A spring-loaded indexing mechanism allows for rotary indexing of the sample at 90° spacing. This, combined with the linear indexing of the BSC-IB indexing base, results in precisely cut specimens in accordance with the listed codes and standards. All specimens are held in place until the last cut is made. Then, loosening of the clamp allows the bend specimens and discards to be removed. Other than brushing or flushing chips away, the fixture is ready for loading of the next sample.

Typical cutting time is 2-5 minutes per bend specimen when using an automatic saw. Indexing time is a matter of seconds.

Mandrels:

All mandrels are designed to meet the listed codes and standards. The stocked part numbers are listed below and on the price list. All part numbers are designated by pipe diameter and schedule or wall thickness.

  • 2-M-2XS
  • 2-M-2XXS
  • 2-M-2.75X.63
  • 6-M-6STD
  • 6-M-6XS
  • 6-M-6XXS

Other special mandrels can be manufactured to order.

PIPE MANDREL SETS

A pipe template is required for each thickness of saw blade to be used. A pipe template can be used for more than one mandrel set, but the mandrel set and template must be for the same type and width of specimen.

2-M-2STD
2″ STD Pipe Mandrel Set. For cutting 3/4″ face and root bend specimens with the BSC-2 pipe fixture.
$975.00

2-M-2XS
2″ XS Pipe Mandrel Set. For cutting 3/4″ face and root bend specimens with the BSC-2 pipe fixture.
$1040.00

2-M-2XXS
2″ XXS Pipe Mandrel Set. For cutting 3/8″ side bend specimens with the BSC-2 pipe fixture.
$1105.00

2-M-2.75x.63
2-3/4×5/8 Super
Pipe Mandrel Set. For cutting 3/8″ side bend specimens with the BSC-2 pipe fixture.
$1170.00

6-M-6STD
6″
STD Pipe Mandrel Set. For cutting 1-1/2″ face and root bend specimens with the BSC-6 pipe fixture.
$1325.00

6-M-6XS
6″
XS Pipe Mandrel Set.For cutting 3/8″ side bend specimens with the BSC-6 pipe fixture.
$1435.00

6-M-6XXS
6″ XXS Pipe Mandrel Set. For cutting 3/8″ side bend specimens with the BSC-6 pipe fixture.
$1745.00

Pipe Templates:
Templates are designed to meet the listed codes and standards. The stocked part numbers are listed below and on the price list. All part numbers are designated by the BSC prefix followed by the bend specimen width and the cutting blade width. The template dimensions include a factor to add approximately 0.020 inch to the specimen width for clean-up by grinding or sanding.

T-3/8.042
T-3/4.042
T-1-1/2.042
Other special templates can be manufactured to order.

PIPE TEMPLATES

T-3/8.042
3/4″ Pipe Template. For cutting 3/4″ wide face and root bend specimens with a pipe fixture using an 0.042″ thick saw blade.
$105.00

T-1-1/2.042
1-1/2″ Pipe Template. For cutting 1-1/2″ wide face and root bend specimens with a pipe fixture using an 0.042″ thick saw blade.
$105.00

T-1-1/2.042
1-1/2″ Pipe Template. For cutting 1-1/2″ wide face and root bend specimens with a pipe fixture using an 0.042″ thick saw blade.
$105.00

Backing Bar Cutting Fixture

The BBC Backing Bar Cutting Fixture is used to remove excess backing bar material from face, root, or side bend specimens taken from 3/8 to 1 inch thick plate samples. This fixture is not mounted on the BSC-IB, but held in the saw vise as shown in the photo.
The BBC can be inserted in or removed from the saw by the operator without the aid of a hoist. The BSC-IB indexer base and attached plate fixture can remain in place without affecting the operation of the BBC. However, to use the BSC-IB and plate fixtures, the BBC must first be removed from the vise. The vise pressure is released and the fixture is withdrawn. This allows the saw blade to pass through the vise area on its way to the plate fixture at the front of the table. The BBC can remain on the saw table until it is needed again.

There is a reference stop that controls the location of the BBC relative to the blade. This is set initially for first use and for different thicknesses or variations of thickness from one batch to the next. The stop allows the fixture to be quickly reinserted into the vise with no further adjustments when running specimens of the same thickness.

The fixture is intended primarily for 3/8 inch thick root and face bend specimens and 1 inch thick side bend specimens. However, other side bend specimens less than 1 inch thick can also be processed by using shims in the clamps. The clamp supports have two positions; one for 3/8 inch thick specimens and one for thicker specimens.

Another adjustable reference stop is provided to compensate for variations in backing bar thickness. This stop can also be used to adjust how close the blade cuts relative to the base material.

Operation of the fixture requires two steps; loading the specimen and clamping the specimen. The clamps slide out of the way for loading. They are also spring-loaded so that clamping can be accomplished by one hand while positioning the specimen with the other.

Typical cutting time is typically 1 minute or less per bend specimen. Clamping time is 20-30 seconds.

There are no optional accessories required for the operations described here.

BACKING BAR CUTTER

BBC
Backing Bar Cutting Fixture. For cutting the excess backing bar material from plate face, root, or side bend specimens in preparation for final grinding. This fixture is not mounted on the BSC-IB, but held in the saw vise. On most saws, the independent BBC Backing Bar Cutting Fixture can be mounted and used without removing the other fixtures.
$1890.00

Vertical Tilt Saws

Fischer Engineering Company can provide an automatic vertical tilt band saw that will work with the Bend Specimen Cutting System to achieve maximum productivity. It is built for heavy-duty industrial applications. It has a variable speed blade drive, a powered blade brush, and hydraulic head tilt, guide arm, vises and blade tension.

A modified travel stop mechanism is provided to coordinate with the fixtures to automatically control the depth of cut and home position. The home position can be adjusted close to the fixture to minimize the run-in time.

Typical Specifications:

Capacity – Square

18″ H x 22″ V @ 90°

Capacity – Miter 18″ H x 15″ V @ 45°
Blade 15′ x 1-1/4″ x 0.042″
Blade Speed 70-300 SFM
Blade Guides Carbide
Blade Drive 5.0 hp                                
Hydraulic Drive 2 hp, 650 psi
Cutting Pressure 0-300 psi
Feed Rate 0-3 ips
Table Height 38″
Load Capacity 6,000 lbs
Machine Weight 4,600 lbs
Dimensions 104″W x 166″L x 96″H

Typical saws that can be used are as follows:

  • Marvel Series 8, Mark III
  • HEM V100HLM-3
  • HydMech V-18, Series II
  • HydMech V-18APC
  • Marvel Series 81

Options:
A number of options are available. Of these, we recommend the chip conveyor as being most likely to be needed. During production bend specimen cutting, it is possible to generate 3-4 cu ft of chips per shift. The chip conveyor drags the chips out of the pan for easy disposal. This keeps the lower band wheel clear of chips. The conveyor can also be used to allow coolant to drain from the chips before disposal.

VERTICAL TILT BAND SAW

SAW
Heavy duty, hydraulic saw with custom adjustable forward and return blade stops.
POR

OPTION
Manual Chip Conveyor
POR

  • All prices are F.O.B. Dayton, Ohio.
  • Terms: n/30, with approved credit.
  • Prices and Specifications are subject to change without notice.
  • 15% Restocking charge for all returned goods (no returns of special order items).
  • Most major credit cards accepted.
  • The prices listed here are for sales within the US and Canada. Sales to other countries may be higher because of additional costs involved for power modification, international transactions and shipping.

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Send mail tosales@fischerengr.comwith questions or comments about these services.