When using slitting saws there are a few things that can easily be overlooked.
Keep the speed down, it is so easy to think that it is working well only to find
too late that due to the very small amount of metal to absorb the heat that it has
overheated and the cutting edges have been destroyed. This especially with thin saws,
say 2mm and less.
Try to avoid cutting deep slits with thin saws as they can easily flex resulting
in a slit that wanders. If you have no option, increase the depth gradually using
multiple passes. Perhaps even starting with a smaller diameter saw.
The angle plate in Photo 1 has two purposes, to set the part vertical in the first
instance and to provide extra support to prevent the relatively wide saw forcing
the part out of the end of the vice. Similarly, Photo 2.
Only a single slot was needed in Photo 3 but by using the spin indexer which can
also use ER collets I was able to use my square collet jaws in a round collet to
hold the square material.
Photo 4 really needs no comment
I actually find myself using the slitting saw more on the lathe than on the milling
machine as I like working with the saw faces horizontal. The setups in Photos 5,
6 and 7 are examples and need not comment.
Also, Photo 8 and 9 are quite simple in terms of cutting the slit, only the method
of mounting the workpiece worth commenting on. The collets being made are held on
square support pieces enabling them to be easily rotated through 90 degrees for each
slit made. LINK