Cutting Power during Cross-Cutting of Selected Wood Species with a Circular Saw

Abstract

This study assessed the effect of selected factors, such as the feed force (Ff = 15, 20, and 25 N), wood species (beech (Fagus sylvatica L.), English oak (Quercus robur L.), and spruce (Picea abies L.)), and the number of saw blade teeth (z = 24, 40, and 60) on cutting power in the cross-cutting of lumber. The cutting was done using a circular saw with a rotating motion of the saw blade at a constant cutting speed (vc) of 62 m.s-1. The tangentially bucked lumber had a relative humidity (wr) of 12% ± 1% and a thickness (e) of 50 mm. For the experiment, four circular saw blades with SK plates, a uniform diameter (D = 250 mm), and identical angular geometry (angle of clearance (α) = 15°, wedge angle (β) = 60°, and rake angle (γ) = 15°) were used. The saw blades had a different number of teeth (z = 24, 40, and 60), and one saw blade had 24 teeth and a chip limiter. The aim of this study was to expand the knowledge about the resulting cutting performance with different combinations of technological process parameters.

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Kminiak and Kubš (2016). “Cutting power circular saw,” BioResources 11(4), 10528-10539.10528
Cutting Power during Cross-Cutting of Selected Wood
Species with a Circular Saw
Richard Kminiak a,b and Jiří Kubš a,*
This study assessed the effect of selected factors, such as the feed force
(Ff = 15, 20, and 25 N), wood species (beech (Fagus sylvatica L.), English
oak (Quercus robur L.), and spruce (Picea abies L.)), and the number of
saw blade teeth (z = 24, 40, and 60) on cutting power in the cross-cutting
of lumber. The cutting was done using a circular saw with a rotating motion
of the saw blade at a constant cutting speed (vc) of 62 m.s-1. The
tangentially bucked lumber had a relative humidity (wr) of 12% ± 1% and
a thickness (e) of 50 mm. For the experiment, four circular saw blades with
SK plates, a uniform diameter (D = 250 mm), and identical angular
geometry (angle of clearance (α) = 15°, wedge angle (β) = 60°, and rake
angle (γ) = 15°) were used. The saw blades had a different number of
teeth (z = 24, 40, and 60), and one saw blade had 24 teeth and a chip
limiter. The aim of this study was to expand the knowledge about the
resulting cutting performance with different combinations of technological
process parameters.
Keywords: Cutting performance; Bucking lumber; Thrust force; Type of saw blade; Beech lumber; Oak
lumber; Spruce lumber
Contact information: a: Department of Wood Processing, Czech University of Life Sciences in Prague,
Kamýcká 1176, Praha 6 - Suchdol, 16521 Czech Republic; b: Department of Woodworking, Technical
University in Zvolen, T. G. Masaryka 24, Zvolen; *Corresponding author: risko.kminiak@gmail.com
INTRODUCTION
The circular saw is one of the most frequently used wood cutting machines and is
designed for cross-cutting and rip-cutting wood. Sandak and Negri (2005) divide the
operation of cross-cutting into two types, rough cross-cutting and final cross-cutting to size.
The rotating cutting tool plays a fundamental role in sawing, and the saw blade
stays perpendicular to the grain of the wood. In cross-cutting, the edges of the saw blade
teeth shear the wood fibers and form the walls of the seam. The main cutting edges in cross-
cutting form the bottom of the notch groove (Siklienka and Kminiak 2013).
The parameters of the process of wood cutting (energy consumption, dust, noise,
etc.), the resulting product (size accuracy, quality of the surface, etc.), and the produced
wood chips (size, grain size distribution, etc.) depend on the physical and mechanical
properties of the machined material; the shape, size, number of teeth, geometry, sharpness
of the cutting tool; and the technical and technological conditions of the machining process
(Kilic et al. 2006; Barcík and Gašparík 2014; Krilek et al. 2014; Gaff et al. 2015; Kvietková
et al. 2015; Gaff et al. 2016).
The geometry and cutting conditions can reduce the cost of wood cutting by
increasing the cutting capacity of the machine (saw), with the appropriate tool selection
(Řasa and Gabriel 2000; Novák et al. 2011).
The energy intensity of the sawing process is monitored through the cutting power.
According to the standard STN ISO 3002-4 (1995), cutting power is defined as the result

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of the scalar product of the vector of the cutting force (Fc) and the vector of the cutting
speed (vc) at the same time during a certain operation and under certain cutting conditions.
The unit of power is the Watt, which is expressed in N.m.s-1.
This study examined how the operator of the circular saw affects the energy
intensity of the cross-cutting process of beech, oak, and spruce lumber, with the feed force,
and how this force affects the operator holding the handle of the circular saw. This
information is particularly necessary when sawing is performed outside an electric power
distribution system, and it is necessary to plan the capacity of the portable source of electric
power (generator power input). This study also investigated the most frequently used saw
blades to find the most energy-efficient blade for the given type of circular saw.
EXPERIMENTAL
Materials
For the experiment, samples of beech (Fagus sylvatica L.), oak (Quercus robur L.),
and spruce wood (Picea abies L.) were used. The lumber used to produce the samples was
logged in 2012 in Zvolenská kotlina (Slovakia), and the average age of the trees was 45
years. The lumber was cross-cut, with a thickness (e) of 50 mm (± 1 mm) and a relative
humidity (wr) of 12% (± 1%). The lumber was dried in a hot air oven dryer. The lumber
was used to produce test samples (Fig. 1), which had a height (h) of 50 mm (same as the
thickness of the lumber), width (š) of 100 mm (parallel to the grain of the wood), and length
(l) of 150 mm (perpendicular to the grain of the wood). Holes with a diameter (d) of 10
mm were drilled in precisely determined locations for mounting the samples to the plate of
the measuring device. Tangentially cut test specimens from multiple stumps were used,
making sure that the samples were cut from the same position on the trunk, with the same
number of annual rings. The specimens were then sorted according to density, the average
density values of test the specimens. The average density values measured at a 12%
moisture content were:
 Fagus sylvatica L. 680 kg.m-3
 Quercus robur L. 650 kg.m-3
 Picea abies L. 430 kg.m-3
Fig. 1. Experimental samples of beech, oak, and spruce

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Methods
Machinery characteristics
The experimental sawing of the lumber was conducted with a sliding miter saw
with a rotating circular blade (GCM 10S Professional, Bosch, Munich, Germany). The
technical parameters of the sliding miter saw are shown in Table 1.
Saw blade characteristics
Four saw blades with SK (sintered carbide) plates were selected (Fig. 2). The saw
blades had identical diameters (D = 250 mm), identical instrument thickness (b = 3.2 mm),
identical cutting edge geometry (angle of clearance (α) = 15°, wedge angle (β) = 60°, rake
angle (γ) = 15°, bias bevel angle (ξ) = 15°, radial inclination angle (λ) = 7°), and alternate
tooth geometry (WZ). Three of the saw blades were from Extol-Premium (Czech
Republic), and they each had a different number of teeth (Fig. 3): 24, 40, and 60. The fourth
blade was a Speedline-Wood from Bosch (Munich, Germany) with 24 teeth and a chip
limiter (Fig. 2).
Table 1. Technical and Technological Parameters of Sliding Miter Saw (Bosch
GCM 10S Professional)
Cutting capacity (0°)
87 x 305 mm
Cutting capacity (45° miter)
87 x 216 mm
Cutting capacity (45°
incline)
53 x 305 mm
Miter setting
52° L / 62° R
Incline setting
47° L / 0° R
Depth x length x height
78 x 68 x 54 cm
No-load speed
4.700 rpm
Saw blade diameter
254 mm
Saw blade bore diameter
30 mm
Weight
21.5 kg
Rated power input
1.800 W
Vibration emission value
(ah)
1.9 m.s-²
Fig. 2. Saw blades used, from left to right: 24, 40, and 60 teeth; 24 teeth and a chip limiter

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Characteristics of experiment
Because it was impossible to maintain the constant conditions of the experiment by
manual feed, the constant feed force was simulated with an experimental stand (Fig. 3).
In the experimental stand, the movement of the hand was simulated by the
movement of a pull rope, and the feed force was exerted by weights. As reported by
Kminiak and Gaff (2015), the average feed force in cross-cut sawing by a circular miter
saw with manual operation of the saw blade ranges between 13 and 28 N. For the
experiment, a feed force (Ff) of 20 N was used. In the experiment, the test specimens were
split exactly in half by the reciprocating movement of the saw blade.
Fig. 3. Experimental stand. a) General view (1 - circular miter saw, 2 - experimental stand,
3 - Piezo–electric dynamometer with mounted sample); b) detail of the cutting zone
Three basic cross-cutting models were used on the circular miter saw, front face
cutting (M1) (Fig. 4a, b, c), slant front face cutting with the angle of grain cut (φ2) at 90°
(miter cutting) (M2) (Fig. 4b), and slant front face cutting with the φ2 at 45° (M3) (Fig. 4c).
The angle of grain cut (φ2) is the angle of the resultant vector of the cutting speed and the
direction of the wood grain. The experiment was carried out at a constant saw blade cutting
speed (vc) of 62 m.s-1.
Fig. 4. Three basic cross-cutting models were used
Measuring cutting power
The cutting power was measured indirectly by measuring the cutting force on the
monitored level of dynamometer power components, Fy and Fz, exerted by the saw blade
on the cut sample. The measuring apparatus for the measurement of the force included a
a)
b)
a) b) c)

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piezo–electric dynamometer (9257B, Kistler, Ostfildern, Germany) (Fig. 5a), a multi-
channel amplifier (5070A, Brand, City, Country) (Fig. 5b), a 16-bit A/D converter (5697A,
Kistler Instrumente AG, Winterthur, Switzerland) (Fig. 5c), and a PC for evaluation, which
included the software DynoWare (Kistler). The necessary cutting power (Pc) was
determined according to Eq. 1,
Pc (W) = Fc * vc (1)
where Fc is the cutting force (N) and vc is the cutting speed (m.s-1).
a) b) c)
Fig. 5. Block diagram of the monitoring equipment. a) Piezo–electric dynamometer 9257B,
b) multi-channel amplifier 5070A, and c) 16-bit A/D converter 5697A
The cutting performance was monitored and evaluated in terms of the effect of the
wood species, cutting model, type of saw blade used, and feed force at a vc of 62 m.s-1. The
resulting cutting performance values were statistically evaluated by STATISTICA 12
software (Statsoft Inc., Tulsa, OK, USA).
RESULTS AND DISCUSSION
A multi-factor analysis of variance (Table 2) showed that the effect of all the
monitored factors was statistically significant, and the effect of their interaction was
significant as well. The Fisher’s F-test ranked the monitored factors according to statistical
significance, from highest to lowest, in the following order: cutting model, feed force,
wood species, and type of saw blade.
Table 2. Statistical Evaluation of the Effect of Factors and their Interaction on the
Cutting Power
Monitored Factor
Sum of
Squares
Degree of
Freedom
Variance
Fisher's
F-Test
P
Intercept
132967368.00
1
132967368.00
118881.11
0.001
1) Wood species
4818499.08
2
2409249.54
21540.25
0.001
2) Type of saw
1130240.55
3
376746.85
3368.36
0.001
3) Feed force (Ff)
11365981.90
2
5682990.93
50809.61
0.001
4) Cutting model
37325340.20
2
18662670.10
166856.32
0.001
1*2*3*4
16772207.80
24
698841.99
6248.10
0.001
Error
72477.99
648
111.85

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During the experiment, the cutting power values were measured in the range of
45.80 W to 1100.13 W. A one-factor and two-factor analysis of the effects of individual
process factors was conducted on the measured data at a 95% confidence interval. During
evaluation, the material factors (wood species and cutting model) and technical and
technological process factors (type of saw blade and feed force) were analyzed separately.
Effect of wood species
The effect of the wood species on the energy intensity of the process of cross-
cutting is illustrated in Fig. 6. The range of the measured data for individual wood species
is shown in Table 3.
There was no statistically significant difference between beech and oak wood.
Despite the fact that beech wood is diffuse-porous and oak wood is ring-porous, they have
approximately the same density and comparable values of the given properties in terms of
the effect of physical and mechanical properties on the defense mechanisms of the wood.
A comparison of spruce and beech, as well as spruce and oak, showed that the cross-cutting
of spruce was the least energy intensive, which was expected because of the previously
mentioned parameters. Similar conclusions were published by Cristovao et al. (2012).
Table 3. Basic Statistical Characteristics of the Effect of Wood Species on the
Cutting Power
Wood
Species
Cutting Power, PC (W)
Mean
Standard
error
-95.00%
95.00%
N
Beech
497.05
26.14
445.57
548.52
252
Oak
451.52
18.84
414.43
488.62
252
Spruce
309.58
31.72
247.10
372.06
252
Fig. 6. The effect of the wood species on the cutting power
Effect of cutting model
The effect of the cutting model on the energy intensity of cross-cutting for
individual wood species is shown in Fig. 7. The range of the measured data for each cutting
model is shown in Table 4.
beech oak spruce
Wood species
200
250
300
350
400
450
500
550
600
Cutting power Pc (W)

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The energy intensity of the process of cross-cutting increased in the order of front
face cutting (M1), slant front face cutting at a φ2 of 90° (M2), and slant front face cutting
at a φ2 of 45° (M3). In the front face cutting model (M1), the wood elements were cut
perpendicular to the direction of the motion of the saw blade, and the path of the saw blade
was the shortest, equal to the width of the sample.
The increase in cutting power recorded in the slant front face cutting model at a φ2
of 90° (M2) was attributed to two factors based on current knowledge. The first was that
the direction of the saw blade with regard to the material resulted in a longer cutting path.
This caused a higher energy loss due to a larger friction area of the saw blade being in
contact with the cut material. In front face cutting, the saw blade path was equal to the
width of the 15 cm sample, and in slant front face cutting, the saw blade cutting path was
21 cm. Another reason was that the direction of the wood fibers (elements), where the
elements were cut at an angle other than 90°, resulted in a longer path that had to be
overcome to cut the elements. There was an increase in the radial cross-section of these
elements and the ideal circular cross-section of the wood elements became an enlarged
elliptical cross-section. Sadoh and Nakato (1987) reached similar conclusions.
Table 4. Basic Statistical Characteristics of the Effect of the Cutting Model on the
Cutting Power for Different Wood Species
Cutting
Model
Wood
Species
Cutting Power, PC (W)
Mean
Standard
error
-95.00%
95.00%
N
M1
Beech
161.54
14.61
132.48
190.61
84
M2
Beech
496.10
40.89
414.78
577.42
84
M3
Beech
833.50
39.91
754.12
912.87
84
M1
Oak
237.04
12.19
212.79
261.29
84
M2
Oak
386.70
19.13
348.64
424.76
84
M3
Oak
730.83
34.05
663.11
798.55
84
M1
Spruce
109.44
7.18
95.17
123.72
84
M2
Spruce
255.93
6.98
242.04
269.83
84
M3
Spruce
563.37
87.96
388.42
738.31
84
Fig. 7. Two-factor analysis of the effect of the cutting model on the cutting power for each
monitored wood species. M1 is the front face cutting, M2 is the slant front face cutting at φ2 = 90°
(i.e., miter cutting), and M3 is the slant front face cutting at φ2 = 45° (i.e. cutting at a 45° angle).
Wood species: beech oak spruce
M1 M2 M3
Cutting model
0
100
200
300
400
500
600
700
800
900
1000
Cutting power Pc (W)

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The last monitored model, the slant front face cutting at a φ2 of 45°, showed the
largest increase in cutting power, which was partially due to the cutting of wood elements
at an angle other than 90°. The increase in cutting power was mainly due to the 2 cm (29%)
increase in the cutting height of the experimental sample compared to the other two cutting
models, which caused an increase in the number of saw blade teeth in the cross-section.
These findings confirmed the conclusions of Costes and Larricq (2002) and Mikleš et al.
(2010), who found that an increase in the cutting height of materials results in an increase
in cutting power and the force required to cut the wood.
Type of saw blade
The effect of the type of saw blade on the cutting power is illustrated in Fig. 8. The
range of the measured data for the different types of saw blades is shown in Table 5. This
data did not confirm the claims of Prokeš (1982) or Droba and Svoreň (2012), who showed
that an increase in the number of saw blade teeth results in a decrease in the cutting force
required to separate the layer of wood and a decrease in the cutting power (as a result of
the decreased nominal thickness of the wood).
An increase in saw blade teeth from 24 to 40 did not result in a statistically
significant change in cutting power for any of the wood species (Fig. 8). The situation
repeated itself when the number of teeth increased from 40 to 60. In spruce wood, the
cutting power for 60 teeth rose above the value measured for 24 teeth.
Table 5. Basic Statistical Characteristics of the Effect of the Type of Saw Blade
on the Cutting Power
Type of Saw
Blade
Cutting Power, PC (W)
Mean
Standard
error
-95,00%
95,00%
N
z = 24 +OHT
389.00
16.17
357.10
420.89
189
z = 24
409.43
26.30
357.55
461.31
189
z = 40
394.04
24.86
345.00
443.07
189
z = 60
485.07
46.61
393.14
577.01
189
Fig. 8. Two-factor analysis of the effect of the type of saw blade on the cutting power for each
monitored wood species
Wood species: beech, oak spruce
z = 24 +OHT z = 24 z = 40 z = 60
Type of saw blade
100
200
300
400
500
600
700
800
900
Cutting power Pc (W)

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The principle of the given effect was in the basic features of this particular
experiment. Unlike other authors who based their experiments on a constant feed speed
(vf), this study used a constant feed force (Ff), which, in the opinion of these authors,
captured the principle of the manual feed of the saw blade more accurately.
At a constant feed force, the current feed per tooth and the nominal thickness of the
chip depended on the current cutting resistance of the cut material and the resultant cutting
force (vector sum of the cutting force and feed force). The effect of the decomposition of
the resulting cutting force on a number of cutting wedges was also reflected here. More
teeth on the saw blade equaled more teeth in the cut.
It was concluded from these results that for the given combination of material
effects and input process variables, it was equally appropriate to use a saw blade with either
24 or 40 teeth.
In terms of assessing the criteria for the use of a saw blade with a chip limiter, it
was discovered that a saw blade with 24 teeth and a chip limiter achieved the same cutting
power as a saw blade without a chip limiter and with both 24 and 40 teeth. The synergistic
effect of eliminating the potential risk of overloading the saw blade with a thrust force that
is too high spoke in favor of a chip limiter.
The effect of the feed force
The effect of the feed force on the cutting power is shown in the graph in Fig. 9.
The range of the measured data for individual feed forces is shown in Table 6.
The feed force values were selected from practical knowledge, where the feed force
was often too high due to the subjective approach of the saw operator, as well as the high
pneumatic locking system settings, which resulted in the displacement of the saw blade
support on automated cutting lines.
Both cases led to an increased cutting power. This was caused by worse cutting
economics, along with poor quality surfaces that required additional grinding. This
experiment focused on the lowest and highest feed force values at which the sample can be
completely cut without the blade getting jammed in the cut, at set cross-cutting conditions.
Table 6. Basic Statistical Characteristics of the Effect of the Feed Force on the
Cutting Power for Different Types of Saw Blades
Feed
Force,
Ff (N)
Type of Saw
Blade
Cutting Power, PC (W)
Mean
Standard
error
-95.00%
95.00%
N
15
z = 24 + OHT
290.60
24.25
242.14
339.07
63
20
z = 24 + OHT
352.87
25.52
301.85
403.89
63
25
z = 24 + OHT
523.51
25.88
471.79
575.24
63
15
z = 24
300.83
45.44
210.00
391.67
63
20
z = 24
389.77
34.36
321.08
458.46
63
25
z = 24
537.68
50.84
436.06
639.30
63
15
z = 40
254.36
13.36
227.65
281.07
63
20
z = 40
347.42
40.41
266.64
428.20
63
25
z = 40
580.34
53.85
472.68
687.99
63
15
z = 60
186.90
12.38
162.14
211.65
63
20
z = 60
688.62
123.82
441.10
936.14
63
25
z = 60
579.70
45.02
489.71
669.69
63

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Fig. 9. Two-factor analysis of the effect of the feed force on the cutting power for each monitored
saw blade
By increasing the feed force, the time necessary to cut the sample was reduced,
which implied that the feed speed increased. This was shown by a graph of the relationship
between the type of saw blade and the feed force (Ff), and the cutting time (Fig. 10).
Fig. 10. Two-factor analysis of the effect of the feed force on the cutting time for each monitored
saw blade
The cutting power increased along with an increase in the feed force. This increase
in cutting power was attributed to the previously mentioned fact that an increase in the feed
force resulted in an increase in the feed speed. This increased the thickness of the cut layer
and the feed per tooth, which resulted in the need for a greater cutting power to separate
the chips.
Type of saw blade: z = 24 + OHT z = 24 z
= 40 z = 60
15 20 25
Feed force Ff (N)
0
10
20
30
40
50
60
70
Cutting time t (s)
Type of saw blade: z = 24 + OHT z = 24
z = 40 z = 60
15 20 25
Feed force Ff (N)
0
100
200
300
400
500
600
700
800
900
1000
1100
Cutting power Pc (W)

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CONCLUSIONS
1. The cross-cutting process at a constant feed force had its own specifics, and not all
patterns derived from the experiments based on a constant feed speed applied to it.
2. This study pointed out the fact that at a constant feed speed the energy intensity of the
process directly depended on the interaction of the material (density, direction of the
grain, etc.) and the tool (number of active cutting teeth, chip limiter, etc.), which was
further complicated by the fact that the given interaction also determined the nominal
chip thickness. These factors considerably complicated the analysis of the process.
3. The energy intensity of the cross-cutting process increased in the order of spruce,
beech, and oak. The energy intensity of cutting oak and beech was almost identical.
4. The experiment showed that the energy intensity of the process of cross-cutting
depended on the cutting model and increased in the order of front face cutting (M1),
slant front face cutting at a φ2 of 90° (M2), and slant front face cutting at a φ2 of 45°
(M3).
5. These results did not confirm the hypothesis that a higher number of saw blade teeth
results in a decrease in the cutting power necessary to separate the layer of wood,
thereby decreasing the cutting power.
6. For the cross-cutting process of selected wood species, saw blades with both 24 and 40
teeth were equally suitable.
7. The experiment confirmed a direct correlation between the cutting power and feed
force. The cutting power increased with the feed force, and also resulted in a shorter
cutting time.
ACKNOWLEDGMENTS
The authors are grateful for the support of the Cultural and Educational Grant
Agency of the Ministry of Education, Science, Research and Sport of the Slovak Republic
(VEGA č. 1/0725/16) and for the support of the Internal Grant Agency of the Faculty of
Forestry and Wood Science; project A13/16.
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Article submitted: August 25, 2016; Peer review completed: October 15, 2016; Revised
version received and accepted: October 25, 2016; Published: October 31, 2016.
DOI: 10.15376/biores.11.4.10528-10539