Pre-Cast Cut-to-Weight

Powering the Future off Precision Casting

When Precision Is Necessary, Choose Everett

In the high-stakes world of aerospace and investment casting, precision isn’t just a goal—it’s an absolute necessity. Everett Industries rises to this challenge with cutting-edge systems that expand your process controls.

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Key Benefits

Flight-Critical Accuracy

Our precision cutting systems achieve higher tolerances on complex alloys, ensuring accuracy for flight-critical components made from exotic materials.

Advanced Cutting Techniques

Advanced cutting techniques preserve material integrity while integrated data logging ensures full traceability, meeting strict aerospace regulatory requirements.

Programmable Systems

Programmable systems optimize cutting processes for specialized aerospace materials, significantly reducing waste and increasing yield at the mold.

Aerospace Cutting Solutions

Whether you’re shaping the future of flight or crafting precision components, our cutting systems are your steadfast partners in pushing the boundaries of what’s possible.

Features

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Find the Perfect Solution

3 Axis Rotary Saw

The Everett Industrial Solutions SS:30RW is a 30″ (765 mm) diameter wheel, 50HP (37.5kW) programmable abrasive cutoff saw designed for production cutting of round rings from 2″ (50mm) to 24″ (610mm).

Wheel Spindle Power

50HP

(37.5kW)

20HP

(15kW)

Workpiece Diameter

24"

Max

2"

Min

Charge Cutting System

Everett’s Charge Cutting System refines the preparation of investment casting charges, delivering unparalleled precision and efficiency for aerospace applications.

Wheel Spindle Power

50HP

(37.5kW)

20HP

(15kW)

Workpiece Diameter

7"

Max

1"

Min

30/36" Saws

The Everett Industrial Solutions SS:30RW is a 30″ (765 mm) diameter wheel, 50HP (37.5kW) programmable abrasive cutoff saw designed for production cutting of round rings from 2″ (50mm) to 24″ (610mm).

Wheel Spindle Power

75HP

(56kW)

20HP

(15kW)

Workpiece Diameter

11"

Max

7"

Min

Schedule a Consultation Today

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Schedule an Industrial Solutions Consultation

Cut To Length

Download Specs
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The Everett SaferCut® 26”/660 mm diameter wheel, 50HP (37.5kW) semi-automatic, dry abrasive cutoff saw is designed for production cutting of round solids to 6” (150mm) per the specifications set forth below. Its failsafe PLC controls the cutting action through an operator controlled proportional-directional hydraulic system. Optional “cut-to-length/weight” systems set forth below allow for relatively unattended single or multiple-bar processing.
Wheel Spindle Power

50HP

(37.5kW)

20HP

(15kW)

Workpiece Diameter

7”

Max

1”

Min

Highly Productive Solution

The Everett Industrial Solutions Cutoff System is not your typical tool-room type saw. It is designed, tooled, and programmed for production-cutting and when combined with part handling and positioning accessories set forth below, it can be the center of an automated, productive cell. Highly trained and skilled operators are not required and that fact was carefully considered when we designed the health and safety aspects of this production cutting system.

Features

Our programmable bar positioner ensures automatic and accurate processing, minimizing human error and maximizing output.
Navigate complex cutting operations with ease using our intuitive touch screen HMI, designed for operators of all skill levels.
Tailor your cuts to exact specifications by programming precise lengths and quantities, adapting to diverse project requirements.
Our system intelligently tracks good pieces while automatically disregarding stub ends, optimizing material usage and reducing waste.
The saw is built on a structural weldment with fork pockets. The saw head and work holding devices are aligned on a ground top plate mounted to the base. An internal spark arrester baffle decelerates sparks and allows them to fall into the included debris cart integral to the base. Dust and smoke flow freely around the baffle into the optional dust collector or into your central system. The compact design minimizes required floor space.
The saw head is designed for cutting with a nominal 26”/660mm diameter abrasive wheel at up to 14,200sfm or 72m/sec wheel speed (Vc). The saw’s rocker arm is a heavy steel casting or weldment, heat treated, and precision machined for the crucial bearing-to-trunnion shaft alignment that provides for straight, vertical cuts. The rocker arm rotates on a trunnion stand that also acts as the oscillation pivot arm. It is a time-proven design that has survived field testing and has contributed to the Severit-with- Everett reputation for reliability for over 61 years.
The 3,200-rpm rated main wheel spindle drives the 8.5” (216mm) cast iron wheel flange. The abrasive cutoff wheel is mounted on a 1” (25.4mm) arbor shaft and clamped by the outer wheel flange. The wheel flanges are assembled on the shaft and faced and trued as an assembly for balance and straightness. The inner wheel flange is equipped with a 0.625” (16mm) diameter drive pin on a 3” (75mm) bolt circle diameter. For EU machines, the wheel flange is 8.67” (220mm) in diameter (refer to ANSI B7.1, EN 12413 and FEPA for completeguidelines). The wheelspindle is designed for long life with heavy- duty deep groove radial bearings but should it fail or be grooved by a spun wheel, it is designed to be easily replaced from the flange side of the rocker arm…typically in less than 1⁄2 hour…a significant design improvement from legacy Everett catalog saw spindle designs.
A 50 HP (37.5 kW) induction motor equipped witha tachometer and thermistor protection is provided. Spindle motor speed is infinitely variable and rated to 3,200 RPM operating with the Sinamics VFD. Drive includes standard VFD features as well as ProfiSafe communications, Safe Torque Off (“STO”), Safe Stop One (“SS1”) and other safety- related functionality. Motor control system also includes a stand-alone “zero-speed” safety monitoring relay. The drive and PLC monitor cutting power and actual wheel speed and abort overly aggressive cuts to protect the operator and machine.
With the VFD data monitoring capabilities, the saw control system provides your operator process feedback in real time to protect the operator, wheel, work, and saw from overly aggressive cutting. A LED indicator flashes colored and audible codes during the cutting cycle. Green for a moderate process (<80% of drive current use), yellow/magenta during moderately aggressive cutting (>80% but less than 100%) and red for very aggressive cutting (>100%). This feedback helps train the operator to use the power available for fast cutting cycles, but not so much as to shorten the life of the saw and motor…or to shatter the wheel and damage the work or machine.
Equip saw head with precision position sensor to enable wheel diameter tracking based on cut start position. With known wheel diameter, control will adjust the wheel RPM to maintain a constant peripheral wheel speed for consistent cutting performance. With the HMI entries required for cut-to-length/weight (part diameter and cut length/weight), the part height above the table is tracked which allows the control to prevent saw from feeding down below a point where the wheel flange would contact the work piece. Operator forgets to select the new job’s bar diameter? The saw control “looks” for first wheel contact within programmable window and will stop the cycle if part-wheel first contact occurs outside that window. We can’t prevent every unanticipated crash, but we strive to enable the saw control to help you guide your folks toward injury and error free operations.
The saw head is equipped with an oscillating trunnion stand that, program-dependent, can oscillate the wheel front to back during the cut. The oscillator is driven by a motor and gearbox that, when active in the cutting setup, moves the wheel forward and backward, relative to the work piece centerline, approximately 3/8” (10mm) which reduces the effective length of wheel contact, provides for chip evacuation, and cools the cut. Oscillation recommended for cut sections >5% of wheel circumference.
The saw head is fed through the cut by the same industrial-duty hydraulic cylinder (equipped with extremely abrasive environment seals) that has made Everett powerhead saws known for reliability. The hydraulic system is controlled by an appropriately sized power unit complete with pump, reservoir, pressure relief, proportional-directional valve, proportional down- feed pressure override valve, and associated control switches and safety valving. The power unit also controls hydraulic work clamping, if so equipped.
Standard work holding designed for bar and tube applications is shown below. Work piece (cut lengths as short as 4”) is clamped on the infeed side of the cut. Work supports are arranged to match the angles of the in/out-feed conveyors, if so equipped, for constant work height and square cuts. Clamping elements on which the work slides, if any, are hardened, ground, and replaceable for long life and easy replacement. Hydraulic clamp secures round work up to 7” (180mm) diameter.
The saw system’s motors, hydraulics, operations, and ladder logic are controlled by a failsafe PLC and associated failsafe I/O cards. The main spindle motor is controlled by the VFD with dynamic braking. Braking is important for productivity since the door interlocks will not unlock until the zero-speed safety relay detects that the wheel is no longer spinning. Hydraulic motion is coordinated by the PLC through a proportional-directional valve as commanded by the PLC and speed-control potentiometer.
This is a production saw designed to promote injury-free operations in a modern manufacturing environment. The system is designed to adhere to the best functional safety practices (ISO13849) and to be EN Machinery Directive compliant. The safety systems were designed based on a detailed and comprehensive formal risk assessment to ISO12100. The vice clamps and cutting area are fully protected in the interlocked machine enclosure for safety and to contain smoke and debris. Easy access, interlocked doors allow for easy wheel change and clean up yet protect your operator from the common dangers of an open, tool room chop saw originally designed for highly skilled operators. Safety interlocks prevent automatic operation of the saw if the guarding is not secured or if the wheel is turning. Cycle start and power work clamping, if so equipped, requires two-handed control for operator safety.

Specifications

Maximum Workpiece Diameter

5” (125 mm)

Minimum Workpiece Diameter

1/4” (6 mm) Standard Configuration

Minimum Workpiece Cut Length (with dual sided clamping)

1/2” (12.7mm)

Typical Inconel Cutting Speed

2 sec/square in

Wheel Spindle Power

20 hp (7.5-15kW)

Wheel Peripheral Speed (if wheels rated accordingly)

13,000 sfm (65 m/s)

Wheel Flange Diameter (US/EU)

4”/5.4” (102, 135mm)

Rapid Return Speed

> 10”/sec (254mm/sec)

Total Elect. Requirements (standard saw)

35 kVA

Voltage (transformers available for other voltages)

480 V

Typical Shipping Weight

4,000 lbs

Machine Dimensions

97”W x 120”D (2.5m x 3m)

Workholding Height

39” (1 m) above floor

Guards

Painted Steel

Standard Cutoff Wheel Range

Outside Diameter

16” (400 mm)

Width

0.130” (3.25 mm)

Bore

1” (25.4 mm)

Get SaferCut Today

Download Brochure
Contact Us

30/36" Saws

Download Specs
Contact Us
The 36” (915 mm) diameter wheel, 75HP (56kW), single-axis abrasive cutoff saw is equipped with a work envelope for economic production cutting of solid round bars from 2” to 6” diameter (machine travels will allow cutting an 11” round with a new wheel). Horizontal axis (saw blade in/out) motion is achieved through PLC-operated proportional valve and hydraulic cylinder based on pre-programmed feed rates or operator entered speeds.
Wheel Spindle Power

75HP

(56kW)

20HP

(15kW)

Workpiece Diameter

11”

Max

7”

Min

Highly Productive Solution

Everett Industrial Solution systems are machine tools…not tool-room or catalog saws. They are designed and built to be dynamically stiff to meet international machine tool standards for a minimum of 15-years of productive life and aggressive, productive hands-off, cutting of aerospace alloy bars.

Features

PLC-operated hydraulic system for smooth, accurate cuts on high-strength alloys
Closed-loop feedback ensures tight tolerances for superalloy components
CutSense technology provides continuous feedback for consistent performance across varying alloy compositions
Fully enclosed design protects operators from high-temperature swarf and debris
The saw is built on a structural weldment in the horizontal cylindrical grinder orientation. The Y-axis saw head weldment slide travels on ground linear ways and bearing cars for rigidity and alignment. All ways exposed to falling objects or cutting debris are protected with impact-resistant way covers. Ways behind the cutting zone are covered with traditional bellows to protect them from incidental dust and debris. The base is concrete filled for mass damping to provide dynamic stiffness.
The saw head is designed for cutting with a nominal 36”/914mm-diameter abrasive wheel at up to 14,200sfm or 72m/sec wheel speed (Vc) fixed, or if the variable frequency drive option is purchased, at up to 16,000sfm/80m/s with constant Vc based on wheel diameter tracking. The Y-axis hydraulic cylinder actuates the saw spindle in/out motion perpendicular to the work axis.
The 3,500-rpm rated main wheel spindle drives the 12” (305mm) cast iron wheel flange. The abrasive cutoff wheel is mounted on a 1.75” (44.5mm) arbor shaft and clamped by the outer wheelflange. The wheelflanges are assembled on the shaft and faced andtrued as an assembly for balance and straightness. The inner wheel flange is equipped with a 0.437” (11mm) diameter drive pin on a 5.5” (140mm) bolt circle diameter. The wheelspindle isself-contained, fully protected with labyrinth seals and held in the housing with a precision, bolt-in cap for ease or repair/replacement as shown below.

A 75HP (55kW), severe duty, cast iron, 1780rpm, NEMA premium efficiency induction motor with a tachometer and thermistor protection is provided as standard. The spindle motor speed is infinitely variable and rated to 3,200 RPM to be able to achieve constant Vc of 16,000sfm/80m/s at a wheel diameter down to 22” or at 12,000sfm/60m/s at 16.5”. The drive includes standard VFD features as well as ProfiSafe communications, Safe Torque Off (“STO”), Safe Stop One (“SS1”), Safe Limited Speed (SLS) and other safety-related functionality. Motor control system also includes a stand-alone “zero-speed” safety monitoring relay. The drive and PLC monitor cutting power and actual wheel speed and can abort overly aggressive cuts to protect the operator and machine.

Using dynamic braking, the main spindle motor is rapidly stopped at the end of cut by the VFD. Braking is important for productivity since the door interlocks will not unlock until the zero-speed safety relay detects that the wheel is no longer spinning. For automated installations, the wheel “hovers” over the work piece and remains running during part repositioning to minimize cycle time.

The saw control system provides your operator process feedback in real time to protect the operator, wheel, work, and saw from overly aggressive cutting. A LED indicator flashes colored and audible codes during the cutting cycle. Green for a moderate process (<80% of drive current use), yellow/magenta during moderately aggressive cutting (>80% but less than 100%) and red for very aggressive cutting (>100%). This feedback helps train the operator to use the power available for fast cutting cycles, but not so much as to shorten the life of the saw and motor…or to shatter the wheel and damage the work or machine.

For setup and wheel change, the Y-axis is positioned by the operator jogging buttons on the operator station which actuates a proportional directional valve (provided safety interlock conditions are met). For semi-automatic cutting cycles, the PLC controls all clamping and axis movement according to the selected speed settings.

The hydraulic system is energized by an appropriately sized power unit complete with variable displacement pump, reservoir, pressure relief valve, proportional-directional valves, counterbalance circuits, pressure override circuits, and associated control switches and safety valving. The power unit also controls hydraulic work clamping, if so equipped.

Depending on final material handling option selection, bars to be cut would be clamped in a vise by a hydraulically or pneumatically actuated clamp on the appropriate side and the cutting wheel depending on the cut type i.e. leading/trailing end trim, middle cut, etc. The outfeed side of the vise is typically set 0.020-0.040” low to the infeed side to minimize potential blade pinching. With the possibility of 500-pound stub pieces an extraction system is included to assist an operator with removal.
The saw system’s safety system, motors, hydraulics, operations, and ladder logic are controlled by a failsafe PLC and associated failsafe I/O cards. Hydraulic motion is coordinated by the PLC through a proportional-directional valve as commanded by the PLC.

System allows operator to program the finish part lengths and process multiple cuts on a bar. An up to 25’ (7.6m) working length raw stock canted infeed roller conveyor and programmable bar positioner is provided for automatic bar processing. Includes a hand-held touch screen HMI for base loader/positioner and for interface with the saw operations. Allows operator to program cut lengths and number of cuts. Saw system will then cut bar to programmed lengths and keep track of number of good pieces (ignores stub ends).

Roller conveyor is made up of replaceable 2.75”Dx0.3” wall rollers on A80 double-shielded bearing on 1” hex axles on 7.5” centers set 1-5/8”low in 8”@11.5# channel frames. Conveyor sized for stock weighing up to 5,000 lbs (2,275 kg) and is rated for rolling 4,300#/ft. When a raw bar is manually or automatically loaded, the AC, absolute encoder, servo motor and gear box driven pusher advances the raw bar to a flip- up stop to establish overall length. The stop then retracts, and the bar is advanced into the cut position. Once at cut position, the bar is clamped, and cut. The bar then advances to the next cut position thereby pushing the cut piece out of the cut zone and on to the exit conveyor. The operator controls the part length, stub end disposition, and number of cut pieces through job menu entries on the touchscreen HMI. The system can be programmed to flash a light and make audible sounds when saw blade needs to be changed, when bar feeder is empty, or when a short bar-end needs to be manually extracted.

Provide 16’ working length outside machine of chain driven live roller conveyor to accept cut product. Cut parts will be transported to far end of exit conveyor and escaped into bundling tough. Bundling trough to be equipped with spring shock absorbers to disperse load of falling bars. Trough surfaces to be lined with replaceable, anti-mar material.
This is a production saw designed to promote injury-free operations in a modern manufacturing environment. The system is designed to adhere to the best functional safety practices (ISO13849) and to be EN Machinery Directive compliant. The safety systems were designed based on a detailed and comprehensive formal risk assessment. The work envelope and cutting area are fully protected in the interlocked machine enclosure for safety and to contain smoke and debris. Easy access, interlocked doors allow for easy wheel change and clean up yet protect your operator from the common dangers of an open, tool room chop saw originally designed for skilled operators. Safety interlocks prevent automatic operation of the saw if the guarding is not secured or if the wheel is turning. Cycle start and power work clamping, if so equipped, requires two-handed control for operator safety.

Specifications

Maximum Workpiece Diameter

5” (125 mm)

Minimum Workpiece Diameter

1/4” (6 mm) Standard Configuration

Minimum Workpiece Cut Length (with dual sided clamping)

1/2” (12.7mm)

Typical Inconel Cutting Speed

2 sec/square in

Wheel Spindle Power

20 hp (7.5-15kW)

Wheel Peripheral Speed (if wheels rated accordingly)

13,000 sfm (65 m/s)

Wheel Flange Diameter (US/EU)

4”/5.4” (102, 135mm)

Rapid Return Speed

> 10”/sec (254mm/sec)

Total Elect. Requirements (standard saw)

35 kVA

Voltage (transformers available for other voltages)

480 V

Typical Shipping Weight

4,000 lbs

Machine Dimensions

97”W x 120”D (2.5m x 3m)

Workholding Height

39” (1 m) above floor

Guards

Painted Steel

Standard Cutoff Wheel Range

Outside Diameter

16” (400 mm)

Width

0.130” (3.25 mm)

Bore

1” (25.4 mm)

Get SaferCut Today

Download Brochure
Contact Us

Charge Cutting System

Download Specs
Contact Us
The Everett SaferCut® 26”/660 mm diameter wheel, 50HP (37.5kW) semi-automatic, dry abrasive cutoff saw is designed for production cutting of round solids to 6” (150mm) per the specifications set forth below. Its failsafe PLC controls the cutting action through an operator controlled proportional-directional hydraulic system. Optional “cut-to-length/weight” systems set forth below allow for relatively unattended single or multiple-bar processing.
Wheel Spindle Power

50HP

(37.5kW)

20HP

(15kW)

Workpiece Diameter

7”

Max

1”

Min

Highly Productive Solution

The Everett Industrial Solutions Cutoff System is not your typical tool-room type saw. It is designed, tooled, and programmed for production-cutting and when combined with part handling and positioning accessories set forth below, it can be the center of an automated, productive cell. Highly trained and skilled operators are not required and that fact was carefully considered when we designed the health and safety aspects of this production cutting system.

Features

The saw is built on a structural weldment with fork pockets. The saw head and work holding devices are aligned on a ground top plate mounted to the base. An internal spark arrester baffle decelerates sparks and allows them to fall into the included debris cart integral to the base. Dust and smoke flow freely around the baffle into the optional dust collector or into your central system. The compact design minimizes required floor space.
The saw head is designed for cutting with a nominal 26”/660mm diameter abrasive wheel at up to 14,200sfm or 72m/sec wheel speed (Vc). The saw’s rocker arm is a heavy steel casting or weldment, heat treated, and precision machined for the crucial bearing-to-trunnion shaft alignment that provides for straight, vertical cuts. The rocker arm rotates on a trunnion stand that also acts as the oscillation pivot arm. It is a time-proven design that has survived field testing and has contributed to the Severit-with- Everett reputation for reliability for over 61 years.
The 3,200-rpm rated main wheel spindle drives the 8.5” (216mm) cast iron wheel flange. The abrasive cutoff wheel is mounted on a 1” (25.4mm) arbor shaft and clamped by the outer wheel flange. The wheel flanges are assembled on the shaft and faced and trued as an assembly for balance and straightness. The inner wheel flange is equipped with a 0.625” (16mm) diameter drive pin on a 3” (75mm) bolt circle diameter. For EU machines, the wheel flange is 8.67” (220mm) in diameter (refer to ANSI B7.1, EN 12413 and FEPA for completeguidelines). The wheelspindle is designed for long life with heavy- duty deep groove radial bearings but should it fail or be grooved by a spun wheel, it is designed to be easily replaced from the flange side of the rocker arm…typically in less than 1⁄2 hour…a significant design improvement from legacy Everett catalog saw spindle designs.
A 50 HP (37.5 kW) induction motor equipped witha tachometer and thermistor protection is provided. Spindle motor speed is infinitely variable and rated to 3,200 RPM operating with the Sinamics VFD. Drive includes standard VFD features as well as ProfiSafe communications, Safe Torque Off (“STO”), Safe Stop One (“SS1”) and other safety- related functionality. Motor control system also includes a stand-alone “zero-speed” safety monitoring relay. The drive and PLC monitor cutting power and actual wheel speed and abort overly aggressive cuts to protect the operator and machine.
With the VFD data monitoring capabilities, the saw control system provides your operator process feedback in real time to protect the operator, wheel, work, and saw from overly aggressive cutting. A LED indicator flashes colored and audible codes during the cutting cycle. Green for a moderate process (<80% of drive current use), yellow/magenta during moderately aggressive cutting (>80% but less than 100%) and red for very aggressive cutting (>100%). This feedback helps train the operator to use the power available for fast cutting cycles, but not so much as to shorten the life of the saw and motor…or to shatter the wheel and damage the work or machine.
Equip saw head with precision position sensor to enable wheel diameter tracking based on cut start position. With known wheel diameter, control will adjust the wheel RPM to maintain a constant peripheral wheel speed for consistent cutting performance. With the HMI entries required for cut-to-length/weight (part diameter and cut length/weight), the part height above the table is tracked which allows the control to prevent saw from feeding down below a point where the wheel flange would contact the work piece. Operator forgets to select the new job’s bar diameter? The saw control “looks” for first wheel contact within programmable window and will stop the cycle if part-wheel first contact occurs outside that window. We can’t prevent every unanticipated crash, but we strive to enable the saw control to help you guide your folks toward injury and error free operations.
The saw head is equipped with an oscillating trunnion stand that, program-dependent, can oscillate the wheel front to back during the cut. The oscillator is driven by a motor and gearbox that, when active in the cutting setup, moves the wheel forward and backward, relative to the work piece centerline, approximately 3/8” (10mm) which reduces the effective length of wheel contact, provides for chip evacuation, and cools the cut. Oscillation recommended for cut sections >5% of wheel circumference.
The saw head is fed through the cut by the same industrial-duty hydraulic cylinder (equipped with extremely abrasive environment seals) that has made Everett powerhead saws known for reliability. The hydraulic system is controlled by an appropriately sized power unit complete with pump, reservoir, pressure relief, proportional-directional valve, proportional down- feed pressure override valve, and associated control switches and safety valving. The power unit also controls hydraulic work clamping, if so equipped.
Standard work holding designed for bar and tube applications is shown below. Work piece (cut lengths as short as 4”) is clamped on the infeed side of the cut. Work supports are arranged to match the angles of the in/out-feed conveyors, if so equipped, for constant work height and square cuts. Clamping elements on which the work slides, if any, are hardened, ground, and replaceable for long life and easy replacement. Hydraulic clamp secures round work up to 7” (180mm) diameter.
The saw system’s motors, hydraulics, operations, and ladder logic are controlled by a failsafe PLC and associated failsafe I/O cards. The main spindle motor is controlled by the VFD with dynamic braking. Braking is important for productivity since the door interlocks will not unlock until the zero-speed safety relay detects that the wheel is no longer spinning. Hydraulic motion is coordinated by the PLC through a proportional-directional valve as commanded by the PLC and speed-control potentiometer.
This is a production saw designed to promote injury-free operations in a modern manufacturing environment. The system is designed to adhere to the best functional safety practices (ISO13849) and to be EN Machinery Directive compliant. The safety systems were designed based on a detailed and comprehensive formal risk assessment to ISO12100. The vice clamps and cutting area are fully protected in the interlocked machine enclosure for safety and to contain smoke and debris. Easy access, interlocked doors allow for easy wheel change and clean up yet protect your operator from the common dangers of an open, tool room chop saw originally designed for highly skilled operators. Safety interlocks prevent automatic operation of the saw if the guarding is not secured or if the wheel is turning. Cycle start and power work clamping, if so equipped, requires two-handed control for operator safety.

Key Features

Improved yield with optimized cutting programs that reduce waste

Enhanced quality with consistent charge weights

Increased throughput with automated operation that allows 24/7 production

Reduced labor costs with minimal operator intervention required

Specifications

Maximum Workpiece Diameter

5” (125 mm)

Minimum Workpiece Diameter

1/4” (6 mm) Standard Configuration

Minimum Workpiece Cut Length (with dual sided clamping)

1/2” (12.7mm)

Typical Inconel Cutting Speed

2 sec/square in

Wheel Spindle Power

20 hp (7.5-15kW)

Wheel Peripheral Speed (if wheels rated accordingly)

13,000 sfm (65 m/s)

Wheel Flange Diameter (US/EU)

4”/5.4” (102, 135mm)

Rapid Return Speed

> 10”/sec (254mm/sec)

Total Elect. Requirements (standard saw)

35 kVA

Voltage (transformers available for other voltages)

480 V

Typical Shipping Weight

4,000 lbs

Machine Dimensions

97”W x 120”D (2.5m x 3m)

Workholding Height

39” (1 m) above floor

Guards

Painted Steel

Standard Cutoff Wheel Range

Outside Diameter

16” (400 mm)

Width

0.130” (3.25 mm)

Bore

1” (25.4 mm)

Get SaferCut Today

Download Brochure
Contact Us

3 Axis Rotary Saw

Download Specs
Contact Us
The Everett 30” (765 mm) diameter wheel, 50HP (37.5kW) programmable abrasive cutoff saw is designed for production cutting of round rings from 2” (50mm) to 24” (610mm). The parts are mounted in a 16” (400mm) chuck and hydraulically clamped on the OD or ID using machined jaws made by the customer for each part (or family of parts). The work head is positioned axially so the wheel cuts through the runner/sprues at the parting line.
Wheel Spindle Power

50HP

(37.5kW)

20HP

(15kW)

Workpiece Diameter

24”

Max

2”

Min

Highly Productive Solution

The Everett Industrial Solutions Cutoff System is not your typical tool-room type saw. It is
designed, tooled, and programmed for production-cutting and when combined with robotic or
mechanical part handling and positioning accessories, can be the center of a highly automated
production cell. Highly trained and skilled operators are not required and that fact was carefully
considered when we designed the health and safety aspects of this highly automated cutting
system.

Features

The saw is built on a structural weldment with integral fork pockets and wireways.
A strategically placed baffle impinges sparks from the cut and decelerates larger particles so they
drop into the easily removable debris drawer for clean out. The saw head and work holding
devices are aligned on ground top plates mounted to the base. The compact design minimizes
required floor space.

The saw head is designed for cutting with a nominal 30” (765mm) diameter abrasive wheel at up to 14,200 surface feet per minute (SFM) or 72m/sec. The saw’s wheel spindle and motor are mounted on a heavy, machined weldment mounted to a cast iron table. The table is mounted on linear cars and rails mounted to the machine base. Ways are fully protected from debris by telescoping covers. The axis is positioned by a hydraulic cylinder equipped with closed loop position feedback as described below.
The 2,640-rpm main wheel spindle drives the 8.7” (221mm) wheel flange. The abrasive cutoff wheel is mounted on a 1.75” (44.5mm) arbor shaft and clamped by the outer wheel flange. The wheel flanges are assembled on the shaft and faced and trued as an assembly for balance and straightness. The inner wheel flange is equipped with a 0.625” (16mm) diameter drive pin on a 3” (75mm) bolt circle diameter. Refer to ANSI B7.1, EN 12413 and FEPA for complete guidelines.
A 50 HP (37.5 kW) induction motor equipped with a tachometer and thermal feedback is provided. Spindle motor speed is infinitely variable and rated to 2,640 RPM operating with the Sinamics VFD. Drive includes standard VFD features as well as ProfiSafe communications, Safe Torque Off (“STO”), Safe Stop One (“SS1”) and other safety- related functionality. Motor control system also includes a stand-alone “zero-speed” safety monitoring relay. Wheel cutting speed is constant (RPM increases as wheel diameter shrinks) to the speed rating of the spindle and wheel.
The saw and work head axes motion is achieved through the cut by the same industrial-duty hydraulic cylinders (equipped with extremely abrasive environment seals) that have made Everett powerhead saws known for reliability. The hydraulic system is controlled by an appropriately sized Rexroth power unit complete with pump, reservoir, pressure relief, air/oil cooler, proportional-directional valves, and associated control transducers, pressure switches, and safety valving. The power unit also controls the work axial positioning and the chuck clamping, if so equipped.
Programmed cutting cycles are controlled by the Siemens PLC through the Rexroth hydraulic system. The system responds to closed-loop position feedback provided by a Balluff 0.000,04” (1 micron) resolution, magnetostrictive linear position sensor mounted in the cylinder. The sensor is totally enclosed in the cylinder, is non- contact, and is designed specifically for industrial hydraulic environments and duty cycles. Were it to fail, it could be changed out in less than 15 minutes. This system enables the control to perform closed loop position and velocity cutting cycles, constant peripheral wheel speed (limited by maximum spindle speed), and to notify the operator when wheel changes are required.
The work table is equipped with a rotary work head spindle, 40:1 gear box, and servo motor for workpiece rotation. The spindle is mounted in a cast iron housing in permanently lubricated (greased) bearings for long life and smooth motion. The work spindle is driven by a hollow-shaft commercial gear box for continuously-variable work speeds from 0-60 rpm. The system is sized to deliver sufficient torque on a 24” diameter workpiece to overcome the tangential forces of the wheel while aggressively cutting using the full power of the wheel spindle.
The work head is equipped with a 16”-18” chuck for automatic hydraulic ID or OD gripping of the work piece. (Final chuck configuration to be determined based on a review of the range of parts) The sliding jaw chuck includes an actuator and rotary union. Interchangeable soft jaws to be machined by the customer per part or part family.
The saw system’s motors, hydraulics, operations, and programming are controlled by a Siemens SIMATIC failsafe PLC and associated failsafe and conventional I/O cards. Programming is carried out on a 12” Simatic Comfort Panel, full-color, touchscreen HMI. The main spindle ABB/Baldor motor is controlled by a Sinamics G120 VFD with dynamic braking. Hydraulic closed-loop motion is coordinated by a Rexroth HACD drive through the Rexroth proportional- directional valve as commanded by the PLC.

The saw system is controlled by our intuitive Sever-It, menu-based abrasive cutting software. The Sever-It software is comprehensive and controls not only the cutting recipe but also all machine movement, machine monitoring, maintenance, and manual operations of the machine system. The software is equipped with multiple user groups that allow selective access to administrative, maintenance, process engineering, and operator users so the machine operates consistently shift-to-shift and day-to- day. The menu, safety, and cutting routines are proprietary to Everett, no source code is provided.

The Sever-It software automates the machine and operator functions of a typical manual, dirty, noisy, and high residual-risk saw run by a skilled and experienced operator…without the difficulty of hiring, training, and retaining an operator. Standard features include:

  • Automatic wheel diameter tracking.
  • End-of-wheel notification so the operator knows when to be ready to change the wheel.
  • Gap elimination (adjust saw start/end position) through wheel life-no more cutting air.
  • Constant or variable in-feed and work rotation speeds to reflect the amount of material being removed.
  • Constant metal removal rate cutting based on part cross-sectional areas.
  • Adjust the RPM of the wheel as it wears for consistent cutting response—constant SFM.
  • Automatic start and end-of-cut detection, gap elimination, and crash protection.
  • Automatic work clamping before cycle start…no surprises from loose work pieces.
  • Safety check…doors closed and locked or two hands on controls before any automatic motion.
  • Interlocked work area and monitored access doors.
  • Savable, repeatable, password-protected cutting recipes for various materials, shapes, and cross-sections.
This is a production saw designed for injury free operations in a modern manufacturing environment…not a catalogue, tool room saw. The system is designed to adhere to the best safety practices and to be EN Machinery Directive compliant. The safety systems were designed based on a detailed and comprehensive formal risk assessment. The chuck and cutting area are fully protected in the interlocked machine enclosure for safety and to contain smoke and debris. Easy access, interlocked doors allow for easy wheel change and clean up yet protect your operator from the common dangers of an open, tool room chop saw. Safety interlocks prevent automatic operation of the saw if the guarding is not secured or if the wheel is turning. Cycle start requires two-handed control, including actuation of the clamps, for operator safety.

Key Features

Sophisticated cutting routines

Simple changeover and process controls

Wheel diameter tracking

A machine learning algorithm for improved performance

Advanced system protection features

Specifications

Maximum Workpiece Diameter

5” (125 mm)

Minimum Workpiece Diameter

1/4” (6 mm) Standard Configuration

Minimum Workpiece Cut Length (with dual sided clamping)

1/2” (12.7mm)

Typical Inconel Cutting Speed

2 sec/square in

Wheel Spindle Power

20 hp (7.5-15kW)

Wheel Peripheral Speed (if wheels rated accordingly)

13,000 sfm (65 m/s)

Wheel Flange Diameter (US/EU)

4”/5.4” (102, 135mm)

Rapid Return Speed

> 10”/sec (254mm/sec)

Total Elect. Requirements (standard saw)

35 kVA

Voltage (transformers available for other voltages)

480 V

Typical Shipping Weight

4,000 lbs

Machine Dimensions

97”W x 120”D (2.5m x 3m)

Workholding Height

39” (1 m) above floor

Guards

Painted Steel

Standard Cutoff Wheel Range

Outside Diameter

16” (400 mm)

Width

0.130” (3.25 mm)

Bore

1” (25.4 mm)

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