Band Saw Blade Speed Chart: TPI, Material, and Cut Compatibility
You need to know the right blade speed and TPI for the material you are cutting. You have a band saw with variable speed and you are not sure what SFPM to set. You also need to choose the right TPI for the material thickness. Getting either one wrong will give you poor cuts, short blade life, or both. You need a reference chart that covers the common materials and thicknesses.
Blade speed (measured in surface feet per minute, or SFPM) and TPI (teeth per inch) are the two most important variables in band saw cutting. Getting both right for the material you are cutting is essential for cut quality, blade life, and cutting efficiency.
Blade Speed Chart by Metal
| Metal | Speed (SFPM) | Notes |
|---|---|---|
| Mild steel | 200 to 350 | Start at 200, increase if cut is clean |
| Stainless steel | 60 to 150 | Start at 60, use flood coolant |
| Tool steel | 80 to 150 | Start at 80, use flood coolant |
| Cast iron | 150 to 250 | Dry cutting is acceptable |
| Aluminum | 200 to 400 | Use WD-40 or cutting fluid |
| Brass | 200 to 350 | Light feed, can grab |
| Copper | 200 to 350 | Light feed, can grab |
| Bronze | 150 to 250 | Similar to brass |
Rule: Start at the low end of the speed range. If the cut is clean and the blade is holding up, increase speed. If the blade dulls quickly or the cut is rough, reduce speed.
Blade Speed Chart by Wood
| Wood Type | Speed (SFPM) | Notes |
|---|---|---|
| Softwood | 3000 to 5000 | Standard for 14-inch saws |
| Hardwood | 2500 to 4000 | Reduce speed for dense hardwoods |
| Exotic hardwood | 2000 to 3500 | Slow speed prevents burning |
| Plywood | 3000 to 5000 | Similar to softwood |
| MDF | 3000 to 5000 | Watch for gumming |
| Green wood | 2000 to 3500 | Lower speed for wet wood |
Note: Most woodworking band saws run at a single speed (typically 2500 to 3500 SFPM). Variable speed is rare in woodworking saws but useful for dense or exotic hardwoods.
TPI Selection by Material Thickness
Metal Cutting
| Material Thickness | TPI | Notes |
|---|---|---|
| Under 1/8 inch | 18 to 24 TPI | Fine teeth prevent grabbing |
| 1/8 to 1/4 inch | 14 to 18 TPI | Good balance for thin stock |
| 1/4 to 1/2 inch | 10 to 14 TPI | General purpose |
| 1/2 to 1 inch | 8 to 10 TPI | Medium thickness |
| 1 to 2 inches | 6 to 8 TPI | Coarse teeth for thick stock |
| 2+ inches | 4 to 6 TPI | Maximum chip clearance |
Wood Cutting
| Material Thickness | TPI | Notes |
|---|---|---|
| Under 1/4 inch | 10 to 14 TPI | Fine teeth for thin stock |
| 1/4 to 1/2 inch | 6 to 10 TPI | General purpose |
| 1/2 to 1 inch | 4 to 6 TPI | Good balance |
| 1 to 2 inches | 3 to 4 TPI | Medium thickness |
| 2+ inches | 3 TPI (hook) | Resawing and thick stock |
Rule of thumb: At least 3 teeth should be in the material at all times. For 1/4 inch material, you need at least 12 TPI. For 1 inch material, you need at least 3 TPI.
Combined Speed and TPI Chart for Metal
| Metal | Thickness | Speed (SFPM) | TPI |
|---|---|---|---|
| Mild steel | Under 1/4 inch | 200 to 250 | 14 to 18 |
| Mild steel | 1/4 to 1 inch | 250 to 350 | 10 to 14 |
| Mild steel | 1 to 2 inches | 200 to 300 | 8 to 10 |
| Mild steel | 2+ inches | 200 to 250 | 6 to 8 |
| Stainless steel | Under 1/4 inch | 60 to 80 | 14 to 18 |
| Stainless steel | 1/4 to 1 inch | 80 to 120 | 10 to 14 |
| Stainless steel | 1 to 2 inches | 60 to 100 | 8 to 10 |
| Aluminum | Under 1/4 inch | 300 to 400 | 14 to 18 |
| Aluminum | 1/4 to 1 inch | 300 to 400 | 10 to 14 |
| Aluminum | 1 to 2 inches | 250 to 350 | 8 to 10 |
| Cast iron | Under 1/4 inch | 150 to 200 | 14 to 18 |
| Cast iron | 1/4 to 1 inch | 200 to 250 | 10 to 14 |
| Cast iron | 1 to 2 inches | 150 to 200 | 8 to 10 |
| Brass | Under 1/4 inch | 200 to 300 | 14 to 18 |
| Brass | 1/4 to 1 inch | 250 to 350 | 10 to 14 |
| Brass | 1 to 2 inches | 200 to 300 | 8 to 10 |
Tooth Profile Selection
Hook Tooth (Positive Rake)
The tooth leans forward. Cuts aggressively. Best for: Thick stock, production cutting, stainless steel. Advantages: Fast cutting, good chip clearance. Disadvantages: Can grab in thin material.
Skip Tooth (0 Degree Rake)
The tooth is straight up. Large gullet for chip clearance. Best for: General purpose, thin to medium stock. Advantages: Good chip clearance, less aggressive than hook tooth. Disadvantages: Slower than hook tooth in thick material.
Regular Tooth (Slight Negative Rake)
The tooth leans slightly backward. Cuts slower, produces the smoothest finish. Best for: Thin material where surface finish matters. Advantages: Smoothest cut, least likely to grab. Disadvantages: Slowest cutting.
Variable Pitch
Variable pitch (like 10/14) alternates between two tooth spacings. This breaks up harmonic vibration, reduces noise, and produces smoother cuts. It also lets one blade handle a range of material thicknesses.
When to use variable pitch:
- When you cut mixed material thicknesses
- When cutting thick solid bar where vibration is a problem
- When you want one blade for all tasks
Blade Material Compatibility
Bi-Metal M42
Can cut: Mild steel, stainless steel, aluminum, brass, copper, cast iron. Maximum material hardness: RC 38 to 40. Best for: General metal cutting.
Bi-Metal M51
Can cut: Same as M42 plus harder alloys and tool steel up to RC 42. Best for: Stainless steel, harder alloys.
Carbide-Tipped
Can cut: All metals including tool steel up to RC 50 to 55. Best for: Production cutting, hard materials.
Carbon Steel
Can cut: Wood, plastic, non-ferrous metals at low speed. Best for: Wood cutting only.
Saw Type Compatibility
Portable Band Saws (Metal Cutting)
Speed: Fixed or variable, typically 200 to 550 SFPM. Blade length: 32-7/8, 35-3/8, or 44-7/8 inches. Best for: On-site metal cutting, pipe, conduit, unistrut.
Horizontal Metal Cutting Saws
Speed: Variable, typically 60 to 350 SFPM. Blade length: 64-1/2 to 144 inches depending on saw size. Best for: Straight cuts in bar stock and pipe.
Vertical Metal Cutting Saws
Speed: Variable, typically 50 to 1000 SFPM. Blade length: Varies by saw. Best for: Contour cutting, notching, irregular shapes.
Woodworking Band Saws
Speed: Single speed, typically 2500 to 5000 SFPM. Blade length: 59-1/2 to 144 inches depending on saw size. Best for: Wood cutting only. Cannot cut metal (too fast).
Blade Break-In
New bi-metal and carbide-tipped blades need a break-in period. Run the first 10 to 20 cuts at half feed pressure. This lets the tooth tips wear evenly and prevents chipping. Skipping break-in can reduce blade life by 30 to 50 percent.
FAQ
What speed should I use for cutting mild steel?
200 to 350 SFPM. Start at 200 and increase if the cut is clean and the blade is holding up.
What speed should I use for cutting stainless steel?
60 to 150 SFPM. Start at 60 and use flood coolant. Stainless work-hardens if the blade rubs instead of cutting.
What TPI should I use for cutting 1/2 inch steel?
10 to 14 TPI. At least 3 teeth should be in the material. For 1/2 inch, 6 TPI gives 3 teeth in the material, but 10 to 14 TPI gives a better surface finish.
What is the difference between hook tooth and skip tooth?
Hook tooth leans forward and cuts aggressively. Best for thick stock. Skip tooth is straight up and is less aggressive. Best for general purpose.
Should I use variable pitch blades?
If you cut mixed material thicknesses, yes. Variable pitch (like 10/14) handles a range of thicknesses with one blade and reduces vibration.
Can I use a wood band saw for metal cutting?
No. Wood saws run at 2500 to 5000 SFPM, which is too fast for metal. You need a saw with variable speed that can run at 60 to 350 SFPM for metal.
References
- LENOX Tools. “Band Saw Blade Speed and Feed Guide.” LENOX Industrial Division.
- MK Morse. “Blade Speed Recommendations by Material.” MK Morse Company.
- Starrett. “Band Saw Blade Selection Chart.” L.S. Starrett Company.
- Sandvik. “Band Saw Blade Technology Guide.” Sandvik Materials Technology.
- Practical Machinist. “Band Saw Speed and Feed Calculator.” practicalmachinist.com.
