Precision Cutting for Casting Perfection
Everett Industries stands at the forefront of this challenge, offering cutting solutions that transform raw castings into flawless components with unparalleled efficiency.Whether you’re dealing with intricate investment castings or heavy-duty industrial components, our solutions ensure that every cut contributes to your product’s quality.
Our cutting solutions reduce scrap rates by increasing your repeatability, turning potential waste into profitable components.
Our experience with machine tool design enables us to design systems that can meet your tight tolerances.
Advanced safety features, like our E-Stop Knee Button, provide peace of mind without compromising productivity.
At Everett, we understand that in post casting, precision isn’t just about maintaining tolerances—it’s about preserving the integrity of your castings while maximizing throughput. Our cutting systems, exemplified by the advanced 22″ Foundry Saw, combine powerful motors with high positional accuracy, ensuring clean, precise cuts even on the toughest cast materials.
Designed for precision and versatility, the Casting Parting Saw excels in handling a wide range of cast products. Its operator protection system allows for hands-on processing of complex casting geometries.
(15kW)
(15kW)
mm
Min
When dealing with larger castings, our Vertical Column Cast Parting Saw provides the power and accuracy needed for clean, efficient cuts. Its robust design ensures stability during cutting, maintaining precision even on substantial workpieces.
(37.5kW)
(15kW)
Max
Min
For when laboratory-grade precision is required, our 2-Axis Parting Saw offers unmatched accuracy. Ideal for repeated small to medium cast part trimming, these saws ensure your formerly hands-on parting operation is safer, cleaner, and repeatable.
(10kW)
(15kW)
350mm
Min
The cornerstone of many post-casting operations, our 22″ Foundry Saw is a marvel of versatility and power.
This powerhouse combines the raw cutting force needed for large castings with the precision required for finishing operations, making it an indispensable tool in any foundry’s arsenal.
(56kW)
(15kW)
Max
Min
At Everett, we’re not just keeping pace with post-casting challenges—we’re casting the future of precision cutting. Let us help you transform your raw castings into profit-driving components with unmatched efficiency, quality and safety.
The cornerstone of many post-casting operations, our 22″ Foundry Saw is a marvel of versatility and power.
This powerhouse combines the raw cutting force needed for large castings with the precision required for finishing operations, making it an indispensable tool in any foundry’s arsenal.
(10kW)
(15kW)
350mm
Min
Base saw equipped with lighted, 3-sided hood with roof to contain dust, debris, and to make dust collector more effective. Customer to consult with factory to specify configuration of hood sides to accommodate parts larger than 30” wide. Full enclosure with reach-through swing door and center viewing window also availabe to better protect operator’s face and body. Hood is equipped with roof slot to facilitate over head crane loading of work pieces. Saw can be ordered without enclosure to accomdate larger or longer parts that extend beyond the enclosure or that cannot be accomodated with a modified hood.
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
Outside Diameter
16” (400 mm)
Width
0.130” (3.25 mm)
Bore
1” (25.4 mm)
(10kW)
(15kW)
350mm
Min
The Everett Industrial Solutions Cutoff System is not your typical tool-room type saw. It is
designed, tooled, and programmed for production cutting. Highly trained and skilled operators
are not required and that fact will be carefully considered when we design the updated health and
safety aspects of this cutting system renewal.
The recontroled saw is programmed to operate in four distinct modes:Manual Mode. Operator fixtures part on table, closes door, and starts saw motor, door locks automatically. Operator uses joystick to drive part through wheel or wheel through part at a speed based on how far the joystick is advanced from vertical. Operator shuts off wheel and when safety circuit detects the wheel has stopped spinning, door unlocks.
Original 10kW Deitz induction motor cleaned, stripped of paint, recoated, run in, and completely tested for operation, end play, amperage draw, and insulation integrity. Drive belts and drive pulleys replaced with new. Motor control system upgraded to a Siemens G120C variable frequency drive and a stand-alone “zero-speed” safety monitoring relay.
Programmable Cut Sequences: Store and recall complex cutting patterns for consistent sample preparation across
Integrated Cooling System: Precision-controlled coolant application prevents thermal artifacts, crucial for analyzing heat-sensitive materials.
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
Outside Diameter
16” (400 mm)
Width
0.130” (3.25 mm)
Bore
1” (25.4 mm)
The 30” (765 mm) diameter wheel, 50HP (37.5kW), up to 5-axis abrasive cutoff saw is equipped with a work envelope that is 1500mm wide x 1500mm deep by 925mm high (60” x 60” x 36”) all as set forth below. Part programs are generated by recording axes locations using a teach pendant and menu entry and can be stored for future use. 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 least 15-20 years of productive life and aggressive, productive hands-off, post-cast rough finish cutting of aerospace alloy castings.
(37.5kW)
(15kW)
Max
Min
The saw is designed to process molds on a repeat basis as well as for one-off, manual cutting by an operator using a handwheel. To facilitate “visual” programming, the saw is equipped with a mobile panel that allows the operator/engineer to manipulate the mounted/fixtured part into position for the cut by jogging the rotary and linear axes while observing the laser line mounted on the saw head. Once the part is aligned to the cutting line, the “new part” starting axes positions are saved in the control.
The saw is built on a structural weldment in the “bridge” or “gantry” configuration with the bed carrying the Z-axis worktable (and C- and B-axes) and the bridge the Y- and X-axes. The base is concrete filled for vibration damping mass. The bridge structural members utilize a polymer-filled “tube- in-a-tube” design that provides for high dynamic stiffness by damping cutting-induced vibration.
The linear X-, Y-, and Z-axes travel on ground linear ways and reciprocating bearing cars for rigidity and alignment. Additional cam roller guides and round rail ball bushings may be used as required for compensation for moment loads and weight carrying. All ways exposed to falling objects or cutting debris are protected with impact-resistant way covers. Ways above the cutting zone are covered with traditional bellows to protect them from incidental dust and debris. The compact, bridge design minimizes required floor space.
The saw head is designed for cutting with a nominal 30”/760mm diameter abrasive wheel at up to 16,000sfm or 80m/sec wheel speed (Vc). Minimum wheel size is 16”/400mm. The Y-axis balscrew (with safety servo brake) actuates the saw spindle up/down motion relative to the X-axis bridge cross slide for plunge cuts. For cross cuts, the blade depth is set by the operator by program/joystick using the Y-axis and then the operator/program actuates the X-axis to feed the saw head across the part parallel to the bridge.
The 4,000-rpm rated main wheel spindle is directly driven by the hydraulic motor and drives the 10” (254mm) cast iron 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 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 wheel spindle is self-contained, fully protected with labyrinth seals and held in the housing with a precision, bolt-in cap for ease or repair/replacement.
The cutoff wheel spindle is directly coupled to and driven by a bent-shaft, axial piston fixed displacement motor designed to provide 85 lb-ft of torque at 1,273 RPM (new wheel at 10,000 SFM) and 75 lb-ft at 3,820 RPM (minimum wheel at 16,000 SFM) allowing you to utilize high performance abrasives for productive, efficient, and cost-effective cutting cycles.
This motor system is designed to deliver similar performance to a 50HP electric induction motor without the interference of the physical size and suspended weight of the electric motor (500lbs) on the Y-axis. A motor tachometer, high-performance proportional valves, an accumulator (with safety valving) coupled provide the tools for closed loop, PID motor speed control for consistent cutting performance.
The linear X-, Y-, and Z-axes are actuated by AC servos equipped with encoders for open loop positioning accuracy through precision ball screws.
Provide a 100HP hydraulic power unit with 3000 PSI motor pump running off a 200-gallon elevated steel reservoir complete with typical temperature, pressure, and level sensors as well as pressure relief, low pressure startup, and isolation valves. The HPU unit is equipped with a water/oil shell and tube heat exchanger (running on its own motor/pump at 45GMP) sized to remove 60% of the system heat (approximately 60HP) with 125°F oil and 85°F cooling water. The system includes pressure relief valves, proportional-directional valves, counterbalance circuits, pressure override circuits, and associated control switches and safety valving. The power unit also controls hydraulic clamping of the rotary axes, if so equipped.
The X-axis table comes standard with a 1500mm (60”) round fixture plate or t-slot table and is mounted on a heavy-duty C-axis rotating positioning table constructed on a slewing ring, crossed-roller bearing, ring gear assembly. The drive pinion is controlled by VFD output to a gearhead motor.
In additional to the rotating C-axis, a vertical, servo driven, rotating T-slot faceplate or chuck mounted on a “4th-Axis” spindle is mounted on the perimeter of the C-axis worktable. This allows the work piece to be rotated about a its horizontal axis as well as being positioned at virtually any angle relative to the wheel cut direction. Customer to provide part fixturing/clamping as appropriate or Everett can quote custom designed work holding fixtures or tooling. A variety of faceplates, chucks, pallet mounts, or hard tooling can be designed for a variety of work pieces.
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 hydraulic motor is controlled by the PLC through closed-loop Rexroth HACD drive and proportional valves. Table motion is coordinated by the PLC through AC servos/ballscrews as commanded by the PLC and speed/direction-control joystick potentiometers. During cutting, only one of either the Y- or the X-axes is permitted at one time to prevent wheel breakage…all other axes are fixed in position by the control.
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 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.
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
Outside Diameter
16” (400 mm)
Width
0.130” (3.25 mm)
Bore
1” (25.4 mm)
Designed for precision and versatility, the CPP Saw excels in handling a wide range of cast products. Its advanced control system allows for programmable cutting patterns, ideal for complex casting geometries.
(15kW)
(15kW)
mm
Min
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.
This is a production saw designed to reduce the high residual risk nature of this operation. While the proposed guarding still permits the operator’s hands and arms to be in the enclosed cutting chamber, the front “reach-through” guarding provides improved protection for the operator’s body and face/head versus a traditional, open- front tree cut-off saw. Compared to an open front saw, this saw provides more physical protection to the operator and better contains smoke and debris. When the blade is stopped, the interlocked door allows for easy wheel change and clean up. A safety interlock prevents operation of the saw if the wheel guarding is not secured in place.
Provide a 20HP VFD with dynamic brake to stop the cutting wheel at end of cycle. Provides a Safe Stop One and Safe Torque Off if E-stop is engaged during the cutting cycle. This further reduces residual risk in a safety risk assessment.
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
Outside Diameter
16” (400 mm)
Width
0.130” (3.25 mm)
Bore
1” (25.4 mm)