How To Set Metal Cutting Bandsaw Blade Speed & Feed Rate For Different Materials

Setting the correct blade speed (SFPM – Surface Feet Per Minute) and feed rate for your metal-cutting bandsaw is crucial for achieving clean cuts, prolonging blade life, and maximizing efficiency. Here’s a guide for different materials:

1. Understanding Key Factors

Blade Speed (SFPM): How fast the blade moves (typically 50–350 SFPM for metal).

Feed Rate: How aggressively the blade is pushed into the material (controlled by downfeed pressure or manual feed).

Tooth Pitch (TPI): The number of teeth per inch (finer for thin materials, coarser for thick ones).

2. Recommended Blade Speed (SFPM) by Material

Material	Blade Speed (SFPM)	Notes
Carbon Steel	80–120 SFPM	Harder alloys require slower speeds.
Stainless Steel	60–100 SFPM	Slower for high-hardness grades.
Aluminum	200–350 SFPM	High speed, low feed pressure.
Brass/Bronze	150–300 SFPM	Medium speed, moderate feed.
Copper	200–350 SFPM	Similar to aluminum.
Titanium	50–80 SFPM	Very slow to prevent work hardening.
Cast Iron	80–120 SFPM	Coarse tooth blade recommended.
Tool Steel	50–90 SFPM	Hardened steel needs slower speeds.

3. Feed Rate Guidelines

Too Slow: Causes blade wear due to rubbing.

Too Fast: Leads to blade tooth stripping or breakage.

Optimal Feed: Should produce small, tightly curled chips (not dust or large chunks).

Feed Rate Adjustments:

Soft Metals (Aluminum, Copper): Higher feed rate (moderate pressure).

Hard Metals (Stainless, Tool Steel): Lower feed rate (gentle pressure).

Thin Materials: Reduce feed to prevent tooth stripping.

4. Blade Tooth Selection (TPI)

General Rule: At least 3–6 teeth in contact with the workpiece.

Thin Material (≤1/8″): 14–24 TPI (fine teeth).

Medium (1/8″–1/2″): 10–14 TPI.

Thick (>1/2″): 6–10 TPI (coarse teeth).

Very Thick (>4″): 3–6 TPI.

5. Additional Tips

Use Cutting Fluid: Extends blade life and improves cut quality (especially for steel, stainless, titanium).

Break In New Blades: Run at 50% speed/feed for the first few cuts to condition teeth.

Listen & Observe:

Squealing? → Speed too high or feed too light.

Blade Teeth Stripping? → Feed too heavy or TPI too low.

Manual vs. Hydraulic Feed: Adjust pressure based on material hardness.

6. Example Settings

Material	Blade Speed (SFPM)	Feed Pressure	TPI (Example)
1″ Mild Steel	100 SFPM	Medium	8–10 TPI
1/4″ Aluminum	300 SFPM	High	10–14 TPI
1/2″ Stainless	80 SFPM	Low-Medium	10–12 TPI
2″ Titanium	60 SFPM	Low	6–8 TPI