The Morse Research and Development (R&D) team is changing how the manufacturing industry views band sawing. A process once seen as mature and mainly based on experience is now being studied with data, precise measurements, and scientific methods. At the 2025 UTIS International Congress on Machining, the R&D team presented new research on the “micro-orthogonal” machining behavior of band sawing, drawing the attention of metal-cutting and manufacturing experts worldwide.
Band sawing is typically the first machining step in industries such as automotive, aerospace, and additive manufacturing, where large cast or forged parts need to be cut into usable sizes. Despite its importance, band sawing has not been studied as extensively as other machining processes. Our team set out to change that by looking at band sawing as a micro-machining operation. Each tooth removes only a few microns of material, and our research shows that band sawing behaves like micro-orthogonal cutting. This helps clarify how tooth shape and cutting conditions influence chip formation, cutting forces, and tool life.
The study was conducted by Joseph Tarr, Michael Lambert, Justin Smith, Joshua Critchfield, and Sekhar Rakurty in the Morse R&D lab. The work is practical, not just theoretical; it provides a scientific foundation for improving sawing performance, increasing productivity, and minimizing waste for our customers. By understanding how micro-scale mechanics influence overall results, we can design longer-lasting blades, optimize cutting parameters, and develop more sustainable sawing solutions. By sharing this work internationally, Morse reaffirms its commitment to combining real-world manufacturing experience with scientific research, delivering truly cutting-edge solutions for our customers.