Rubber Foam Tube Cutting With Reciprocating Saw

A client reached out with what seemed to be a simple task: a clean, smooth cut on a long ArmaFlex rubber foam insulation tube with variable lengths and diameters. Here at AIM Joraco, we designed and fabricated a machine consisting of a reciprocating saw attached to a Direct-Aire model 300H press with confinement mandrels and a support cradle.

Process

Because the material is highly compressible, conventional cutting methods could cause deformation and barreling, making it difficult to achieve a consistent, flat cut. We evaluated several cutting methods: Hot wire, band saw, guillotine blade, and reciprocating saw—to determine which approach would provide the cleanest, most consistent cut. The team also tested multiple support methods to find the best way to stabilize the compressible material while still allowing tubes to be easily fed through the machine. Once the reciprocating saw was selected, a custom fixture was designed to securely mount it to the press ram, while the overall machine was kept as compact as possible to fit within the existing press frame. 

Results

The resulting system was designed to accommodate both 6- and 8-inch diameter tubes and cut lengths ranging from 12 to 42 inches. Interchangeable confinement mandrels provide support for different tube diameters, while an adjustable stop and support cradle allow operators to quickly position material for varying cut lengths. Four-sided guarding and an emergency stop were also incorporated to improve operator safety. By properly supporting the material during the cutting process and optimizing cutting speed the system helps minimize deformation, reduce unnecessary blade wear, and make the overall operation easier and more consistent for the operator.

Click here to see it in action. The completed design met the primary objective of producing clean, consistent cuts while minimizing tube deformation, saw wear, and operator effort. 

At AIM Joraco®, we specialize in developing custom press solutions that address the unique challenges of demanding manufacturing applications.

For more details, here's our project summary: Rubber_Foam_Tube_Cutter

About Joraco Press Company

Joraco Press Company has been an innovator in the pneumatic press industry since 1947. The trademarked TOGGLE-AIRE® Series has been the core product of Joraco Press for over 60 years having been installed in thousands of manufacturing facilities all over the world. The past 20 years have seen Joraco Press expand its benchtop pneumatic press products to cover more applications and more force ranges than ever before. Joraco Press Company is a division of Automated Industrial Machine, Inc located in Smithfield, RI. Our products are designed, fabricated, and assembled at the AIM headquarters and as always, the same people who build our presses are always available to help troubleshoot your press.