How to mark the ends of profile pipes for cutting at different angles and the subsequent connection
In the manufacture of structures from profile pipes they often have to be joined at different angles. Cutting “by eye” leads to large errors and connections are obtained flimsy and unsightly. Below we consider a very simple way of marking, cutting by which avoids the disadvantages noted above.
Spread different lengths of profile pipe on a flat surface so that the ends at the joints are connected at different angles.
Connect the profile at right angles
To join two identical segments approximately at right angles, which is not necessary, we measure with a ruler the most distant points on the faces of the ends in their plane.
On a point of contact of the bottom sides of pieces we put a ruler parallel to the imaginary line connecting points of the most distant sides. We set off in both directions half of the distance of the most distant points of the faces and mark them with points.
Using the square, make sure that the segments have the same angle. Draw straight lines through the marked points and the points of the most distant sides up to their intersection with the sides of the segments.
Cut along the obtained line with an angle grinder the ends of the elements and connect them along the line of the cut.
Methods of cutting pipes
To cut profile pipe, including at a certain angle, you can use the following tool:
- Angle grinder. angle grinder (picture above). This method is most often used for domestic purposes, as it is characterized by the simplicity and accessibility of equipment;
- hacksaw for metal. Using a hacksaw is not difficult, but the process of doing the work is quite time-consuming;
Use of a metal saw for cutting profiled pipes
The use of an electric jigsaw and hacksaw is not possible for cutting thick-walled profile pipes or pipes with a large diameter.
- a special machine for cutting pipes. The equipment is most often used by professionals, as it is distinguished by its high cost. Currently, professionals use two types of machines:
- Equipment with mechanical cutting, which is performed by a cutting wheel or a special saw;
- equipment with a laser. Laser cutting is more accurate compared to its mechanical counterparts.
Using a special machine with laser cutting
When choosing any method, it is important to pay special attention to safety. During the cutting of profilpipe metal chips are formed, which can damage the hands and eyes of the master, so before performing the work it is important to wear gloves and goggles.
How to cut profile pipe with an angle grinder
The most popular method of cutting in domestic conditions is the use of an angle grinder. How to cut a profile pipe evenly with an angle grinder? The main problem of performing the work is the correct marking.
To apply the markings can be used:
- tape measure, square, marker (pencil), construction level. The simplest tools can accurately enough to mark the angle of the cut, but during the performance of angular grinding machine can deviate from the specified line (equipment is not supported on a support, and is on weight, that is, in the hands of the master), which will lead to an error. For this reason, this method is used very rarely;
Drawing a marking for the cut with a square
Use a paper template
The simplest device to cut correctly at an angle, for example, for making a greenhouse, is a template made of thick paper.
To make the cut at a right angle (90 °), you need:
- Use a thick sheet of paper to wrap around the pipe and achieve a perfect overlap of the edges;
- fix the sheet in this position;
- cut the profile pipe along the edge of the paper.
To make the cut profilpipe at an angle of 45 °, you must fold a sheet of paper in half (the hypotenuse) and wrap the tube so as to align the acute ends of the resulting triangle.
Professional craftsmen use special computer programs that allow more accurate creation of a paper template for cutting profiled pipes at any angle.
Automatic production of the paper template by computer program
Using the construction diagonal cutter
It is possible to cut profile pipe correctly at any angle by using a construction diagonal cutter. The device is used in the following order:
- Profile pipe is fixed inside the device and aligned at a certain angle;
- Using a built-in hacksaw a preliminary cut is made;
Cutting at an angle with a construction diagonal cutter
The finished measuring tool is of high cost. To reduce the financial costs when performing construction work, you can make an analogue of the construction chisel yourself. For this purpose, a wooden frame with a recess under the pipes is made and, using measuring tools, notches are made at different angles.
Chisel for cutting profiled pipes with their own hands
Watch this video to see what other methods you can use to cut square section pipes.
Peculiarities of cutting pipes longitudinally
Using angle grinder you can make not only cross but also longitudinal cutting of profile pipe. How to cut profile pipe lengthwise? The work is carried out in the following order:
- as with cross cuts, the work begins with a marking. It is important to mark as many reference points on the side of the pipe as possible to obtain the straightest possible line for the trimmer;
Marking a line for a longitudinal cut
- to improve visibility and eliminate the possibility of obtaining an uneven cut, it is recommended to highlight the resulting line for the trimmer (with paint or paint tape);
- the pipe is fixed in place with e.g. clamps. If possible, you can also fix the angle grinder, alternatively with a special stand;
- gradually the cut is made along the set line.
Cutting pipe lengthwise with an angle grinder secured to a stand
Cutting thick-walled profile pipes is performed using a similar technique. Before the execution of the work it is required to fix the tube, which eliminates the possibility of fracture of the workpiece under its own weight.
Which brands can be bent and which cannot
Thus, there are several basic types of aluminum sheet, which may differ significantly from each other in their physical properties and deformation capabilities. So, the most common types are:
- Baked, it has the letter M in the designation, it is the softest grade, so it is perfectly susceptible to deformation, but at the same time easily shrinks and breaks under excessive stress.
- Semi-finished productsThe fifth is called H2 and has stiffer properties than the M grade, it also deforms well and can withstand more than 90 degrees of bending at a time. At the same time, thanks to its high rigidity, it retains its shape well and prevents formation of dents, which is why it is often used as a facing material.
- trimmed, the grade designation contains one letter H. Nagarting. It is a method of giving the sheet steel increased strength through cold welding. To do this, the aluminum sheet is additionally rolled between two rolls on a special machine. This grade bends well at angles of up to 90 degrees and can withstand considerable loads on its surface.
- Hardened or naturally aged, it is usually denoted by the letter T. It’s pretty hard aluminum, so it’s more demanding to work with because it bends when bent to a cold 90-degree angle. It is used for parts and assemblies that work under high loads.
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The basic types of aluminum sheet metal alloys can be arranged as follows:
- 1105 and VD1 technical alloys have a relatively low specific sheet weight and bend easily without problems.
- Aluminum-magnesium alloys are designated by the letters AMG. They are made of aluminum alloy with the addition of magnesium and manganese. AMG is acid resistant and highly bendable, which is why it is mainly used for containers and tanks as well as boat and boat parts.
- Food grade A5 and AD alloys are produced with cages, half cages or annealed marks.
- AMC alloys are specifically designed for the production of complex curved parts, such as car radiators and the like.
- Dural is marked with the letter D. It belongs to the high-strength grades, the main difference being its high resistance to external influences. Dural is virtually impossible to bend, so it is only used in stamping parts.
- Particularly strong B-class aviation alloys are bent by special stamping and pressing technology. They are used in the manufacture of heavy-duty parts in the automotive industry and aircraft construction.
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How to make a bend in the profile pipe at any angle
When you want to make a profile tube element with a 45 degree angle, the two blanks are usually faced at 22.5 degrees, and then welded together. This is a very simple and fast method, but not the most beautiful. In the case where you need to make a smooth bend of a solid pipe without the formation of a sharp outer corner, you can use the following method.
Tools needed:
In the center of the future bend of the profile pipe, the cross line for the trimmer is drawn with a marker under the angle. Such marking is made on all 4 sides of the pipe.Next, you need to make 4 more transverse lines on one of the sides, 2 more to the left and right of the central. They are carried out under the angle with an indentation of half the cross section of the pipe. For example, if it is 40×40 mm, then you should indent with a step of 20 mm, and if 50×50 mm, then 25 mm. The same lines should be applied on the opposite side of the pipe.
Then diagonals are drawn between these lines, as in the photo. As a result they should form the letter “M”. Similar diagonals are made on the opposite side of the pipe. It is important that they are in the same direction.
Next, the pipe is rotated so that the sides with diagonals are on the sides, and then you should draw the extreme lines with a marker, both on the upper side and the back.Now use an angle grinder to make diagonal cuts on both sides. It is most convenient to use a worn cutting wheel for this, as it has a small diameter, which allows you to work finely, without cutting unnecessary.
After cutting the diagonals, it is required to lay the pipe so that the composed or the letter “M” is inverted. The next step is to cut the outermost marks at the top, the turn of the pipe must remain intact. As a result of undercutting, the unnecessary part with two teeth is separated.
If its walls are thick, you have to use a vice. Then you need to weld and grind the joints.
The result is a perfect 45-degree bend without a sharp outer corner, which looks like a factory. This way you can bend the pipes in the manufacture of various frameworks and frames, where safety is important. Accidental collision with a hand or foot on such a bend is less traumatic than a normal bend with a sharp outside angle.
Diffusers
As a rule, a set of angular aluminum LED profile comes with two types of diffusers (screens):
Both types of screen are made of plastic. When choosing a diffuser it is worth considering a fact: a transparent diffuser transmits 95% of the illumination brightness, a matte one. only 70%. In the first case, the task of the screen. to protect the LED strip from damage and external influences. In the second. the diffuser is used not only to protect the backlight from moisture, dust, but also to muffle the emission of light.
In most models of angular LED profiles screens are mounted on the front of the design. click on top, in contrast to other types of mounting systems, where the diffusers are pushed to the end.
Standard sizes
Profile size for LED strip is adjusted to the light source. LED strip has the following dimensions: in width from 8 to 13 mm, in thickness from 2.2 to 5.5 mm, and in length up to 5 meters. For side-lighting strip parameters are slightly different: the width is 6.6 mm, and the height is 12.7 mm. Therefore, the standard size of the construction is, on average, two meters. But the common length is from 1.5 to 5.5 meters. The size of the box in width ranges from 10 to 100 millimeters, the depth of 5-50 millimeters.
Profile dimensions may vary, t.к. Each manufacturer has its own manufacturing technology and standards. In general, products come in the following sizes:
Here we have considered the main types and sizes of profiles for LED strip. We hope that the information provided was useful and interesting for you!
Electric jigsaw
Before working, it is important to make sure that the tool has a saw attached specifically for metal. Of course, a blade for wood will also cut aluminum, but the quality of the cut will leave much to be desired. Profile cutting begins with the back, then in turn saw the side edges.Advantages:
- Electric equipment makes the user’s job easier;
- quality, close to perfect (there will be no burrs, bevels, other defects on the product);
- quickness of work;
- Reusability (with the right saw);
- jigsaws are cheaper than similar devices for cutting aluminum profiles.
Cutting mosaic 45 degrees
How to see (cut, trim) the mosaic at an angle of 45 degrees with a grinder?
You can learn about all the options for washing mosaic at 45 degrees in this article.
Detailed information about hand tools and equipment used for cutting aluminum profiles is described in this material.
Thin aluminum sheet is easy to cut, because almost any tool is suitable. How about, for example, a size angle or an awkward channel? This material describes in more detail the hand tools and equipment used to cut aluminum profiles. The work is complicated by a number of factors, but you can still evenly divide the workpiece.
Cutting a 45-degree mosaic
How to see (cut, trim) a mosaic at a 45 degree angle with a grinder?
You can learn about all the options for washing mosaics at 45 degrees in this article.
Detailed information about hand tools and equipment used for cutting aluminum profiles is described in this material.
Thin aluminum sheet is easy to cut, because almost any tool is suitable for this purpose. What about, for example, a size angle or an awkward channel? This material describes in more detail hand tools and equipment used for cutting aluminum profiles. The work is complicated by a number of factors, but you can still evenly divide the workpiece.
angle grinder
angle grinder. a universal helper, perfectly working on aluminum. It is only important not to confuse a cutting wheel with a grinding wheel, to choose the accessories of small thickness to minimize material loss and protect your hands and face from sparks.Advantages:
- rapidity of work;
- Decent quality of the cut;
- Relative cheapness of the equipment;
- minimum user movement;
- Durability of the tooling, which allows you to repeatedly saw metal profiles.
- possibility of metal burning in the area of the cut;
- without the skills of the work is unlikely to be able to cut evenly;
- To improve the accuracy of the angle grinder is to clamp in a stand, which is not supplied with the tool and are rarely available in stores (the problem is solved if you have a vise).
Now it is worth studying special devices for working on aluminum.
Is it possible to cut profiled sheeting “angle grinder”?
Profiled sheet is expressly forbidden to cut with the tool for three reasons:
- Spectacular sparks that fly out from under the disk in the process, damaging the decorative and protective layer. They get on a polymeric coating, burn it and zinc. In places where sparks hit, corrosion can occur.
- An abrasive disk saws profile sheeting due to friction. As a result, the metal is heated by high temperatures and the polymer and zinc coating along the edges are burned out, which leads to the occurrence of edge corrosion.
- The abrasive disk leaves “torn” edges.
So: “angle grinder” can quickly cut profiled sheeting, but it will become unusable. Therefore, the answer to the question “how to cut profiled sheeting “angle grinder” is simple: no way.
Is it acceptable to cut profiled sheeting with a circular saw??
Cutting profiled decking with a circular saw, even if you will use a diamond disc with fine teeth, is not the best option. This tool cuts the metal due to the heat; the disk melts the edges, and with them. the zinc and polymer coating. Thus, the edges of the sheet are again unprotected from corrosion.
During the cutting process, there are no sparks that burn through the polymer and zinc coatings. But because of the aggressive impact on the sheet edges, we do not recommend this tool.
Methods
When aluminum is processed on a production scale, it is bent in two ways.
- Free. When bending the sheet metal, there is an air gap between the sheet and the pressing tool. This method allows to work with thicker materials and produce products with complex shape, but when working with thin sheets gives a low accuracy of bending.
- Calibration. In this case, there is no air layer between the machine and the aluminum. This allows you to carefully bend thin sheets, but requires a lot of effort and expensive hardware.
It is possible to bend an aluminum sheet at home without the use of expensive tools.